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CLS-M3
Cargo Lift Scale
Installation & Service
Manual
157393 Rev F
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Contents
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com/training
or obtained by calling 715-234-9171 and asking for the training department.
1.0 Introduction.................................................................................................................................. 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Considerations Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Forklift Derating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Forklift Battery and CLS Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 CLS-M3 Power and PC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 iQube2® J-Box Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 Scale Base Installation................................................................................................................ 4
2.1 Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Tools Needed to Install the CLS-M onto the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.1 Unpacking a One Scale Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.2 Unpacking a Two Scale Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Scale Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Connect the Coiled Interface Cable to J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Install Forks onto Scale Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.0 Cable Connections..................................................................................................................... 12
3.1 Routing Coiled Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Pre-installed RS-232 Adapter Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Connecting the Coiled Interface Cable/RS-232 Adapter Cable to Mobile PC . . . . . . . . . . . . . . 13
3.4 Check Scale for Accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.0 Revolution® Interface to CLS-M ...............................................................................................14
4.1 Connect Scale to Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Live Weight Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Leveling Forklift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4.1 Reading Data In Live Weight Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5 EZ Setup/Upload Unit Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.0 Calibration ................................................................................................................................. 27
5.1 Carriage J-Box Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Leveling Forklift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3 Calibrate Scale Using Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3.1 Reading Data In Live Weight Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4 Weights and Measures Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.0 Load Cell Replacement and Flexure Troubleshooting .............................................................. 33
6.1 Required Tools for Replacing a Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Load Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3 Forklift Flexure Troubleshooting - 28" and 34" Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Specifications subject to change without notice. Rice Lake Weighing Systems is an ISO Registered Company.
© Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
July 12, 2016
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7.0 iQube2® J-Box .......................................................................................................................... 42
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars
7.1 iQube2 J-Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2 Download the Serial Number to the J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 iQube2 PCB Board Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4 iQube 2.3 Cross References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.0 Appendix .................................................................................................................................... 47
8.1 Parts Breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.3 Troubleshooting iQube2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ii CLS-M2 Installation Manual
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1.0 Introduction
DANGER
WARNING
CAUTION
Important
WARNING
The Cargo Lift Scale is a rugged, dependable cargo lift scale that can withstand many years of repeated use. When
mounted on a forklift, the CLS-M3 saves time and money by allowing you to weigh loads immediately instead of
carrying the load to a floor scale.
This manual is for trained and qualified personnel responsible for installing and servicing the Cargo Lift Scale
(CLS-M3). This manual covers information on the installation and service of the scale carriage, coiled interface
cable to the mobile PC.
1.1 Safety
Safety Symbol Definitions:
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation that, if not avoided could result in death or serious injury, and
includes hazards that are exposed when guards are removed.
Indicates a potentially hazardous situation that, if not avoided may result in minor or moderate injury.
Indicates information about procedures that, if not observed, could result in damage to equipment or
corruption to and loss of data.
General Safety
Do not operate or work on this equipment unless you have read and understand the instructions and
warnings in the Installation, Operation and Maintenance Manual. Failure to follow the instructions or
heed the warnings could result in injury or death. Contact any Rice Lake Weighing System dealer for
replacement manuals. Proper care is your responsibility.
Failure to heed may result in serious injury of death.
Some procedures described in this manual require work inside the j-box. These procedures are to be performed by
qualified service personnel only.
Take all necessary safety precautions when installing the scale carriage including wearing safety shoes, protective eye
wear, and using the proper tools.
Do not allow minors (children) or inexperienced persons to operate this unit.
Do not operate without all shields and guards in place.
Do not jump on the scale.
Do not use for purposes other then weight taking.
Do not place fingers into slots or possible pinch points.
Do not use any load bearing component that is worn beyond 5% of the original dimension.
Do not use this product if any of the components are cracked.
Do not exceed the rated load limit of the unit.
Do not make alterations or modifications to the unit.
Do not remove or obscure warning labels.
Do not use near water.
Keep hands, feet and loose clothing away from moving parts.
Introduction 1
Page 6
1.2 Considerations Before Installation
Net Capacity
A (B + C) - D (E + F)
=
CB
A
D
G
F
Net
Capacity
H
E
K
J
1.2.1 Forklift Derating
Capacity Reduction Calculation
While the CLS-M3 will fit most typical forklifts, there are considerations that must be taken into account prior to
installation. Due to the extra weight of the CLS-M3, the net lifting capacity of the forklift is reduced by
approximately 10 percent. Use the formula below to calculate the amount to down-rate the lifting capacity and
determine the net capacity of the forklift.
E + G + H
A = Truck Basic Capacity in pounds B = Inches from front wheel center line to fork face
C = Inches from face to truck rating point (usually 24) D = Weight of scale in pounds
E = Inches from front wheel center line to carriage face F = Inches from carriage face to scale horizontal center of gravity (HCG)
G = J + K (inches from carriage face to rear face of load H = Inches from fork face to new truck rating point
J = Thickness of fork K = Thickness of scale
CLS Classes and ID Plates
During the initial sale or installation of the CLS-M3, remind the customer that they must have an updated ID plate
on the forklift stating the new lifting capacity and center of gravity information. This is require3d per OSHA rules
and regulations.
28 inch 34 inch 38 inch
Vertical enter of gravity (VCG) of scale = 8.06 8.06 10.15
Horizontal center of gravity (HCG) of scale = 2.09 2.09 2.83
Effective thickness (ET) of scale = 4.55 4.55 6.06
Weight of scale = 392 420 987
2 Cargo Lift Scale Series
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1.2.2 Forklift Battery and CLS Installation
CAUTION
RS-232 Adapter Cable
Coiled cable
connection
Mild steel
construction
Field replaceable load
cell connectors
Calibration
switch
** Type B USB micro connector for
use with Revolution or USB Micro
A connector for firmware updates
Note
Take into consideration that the indicator power source will be connected directly to the battery of the
forklift. Most typical is 12 volts for propane, gas and diesel forklifts.
12 volt systems must have a negative ground so ensure the forklift has a negative ground electrical
system. The CLS will not operate on a positive ground forklift. Refer to the forklift users manual to further
verify grounding requirements.
The standard CLS scales use 9-36V power supply for use on 12 V batteries. If the forklift is an electric system,
make sure to install:
PN 166162 – DC-DC Converter, CLS
PN 166161 – Power Line Filter, CLS (for static protection)
1.3 CLS-M3 Power and PC Connection
The CLS-M3 receives power from a mobile PC through the RS-232 port, this eliminates the need for a
Communication/Power box.
2
The iQube2 j-box interfaces to Virtui
allows the operator to display weight and zero the scale.
To calibrate and troubleshoot the CLS-M3, Revolution– software has been installed on the mobile PC as well.
The mobile PC receives data and power (5V on pin 9) from the iQube2 j-box through the Coiled Interface Cable,
PN 156295 and RS-232 adapter cable (PN 156296).
software that has been pre-installed on the mobile PCs operating system. It
Figure 1-1. Coiled Interface Cable and Adapter
1. 4 i Qu b e2® J-Box Introduction
The iQube2 j-box sits in an area between the front and back plate of the scale itself providing protection for the
j-box. It comes from the factory pre-wired and no additional work needs to be done to it other than sealing it for
Legal for Trade applications.
Figure 1-2. Two-Channel J-Box on CLS-M Scale
After successful installation (Section 2.0) and calibration (Section 5.0), replace the cover on the scale assembly
and secure with bolt and washer.
Introduction 3
Page 8
2.0 Scale Base Installation
WARNING
CAUTION
This section describes procedures for installing the Cargo Lift Scale base.
Take all necessary safety precautions when installing the scale carriage, including wearing safety shoes
and protective eyewear, and using the proper tools, which are listed in Section 2.4.
The Cargo Lift Scale is shipped from the factory with the scale already calibrated and all settings stored in the jbox. Minimal adjustments and calibration might be necessary once the scale is installed onto the forklift. Those
calibration steps are contained in Section 4.6 on page 36.
2.1 Before Installation
Before installing the CLS on a forklift, the forklift should be in good operating condition for optimal weighing
accuracy. Look for the following items prior to installing the CLS onto a forklift:
•Inspect the forks for any damage.
•Check the locking pin on the forks for proper function.
•Check and adjust the lift chain so the heel of the forks have 1/2 to 1 inch of clearance from the floor when the
carriage is down and the mast is vertical.
•The slot for the center pin should be clear of grease and debris.
•The top cleats of the forklift rest on the top of the scale and should remain clear of grease and debris that
could alter the scale’s performance.
The power/communication box will be connected directly to the battery of the forklift. The CLS scale works with
9-36 VDC power source.
All systems must have a negative ground.
2.2 Tools Needed to Install the CLS-M onto the Forklift
Once the forklift is deemed in good mechanical and operating condition, use the following tools to remove it from
its shipping pallet and install onto the forklift.
Tool Size Purpose of Tool
Allen wrench 4 mm For service only, to remove j-box
Cresent wrench 2 in adjustable For adjusting the shim bolts and jam nuts.
Tin snips or band cutters NA To cut the plastic banding surrounding the CLS while on the pallet.
Torque wrench w/ 1/2" Allen 1/2 in To tighten the cleats to 125 ft-lb.
Electric grinder For grinding the center pin if necessary and the mounting bolts.
Wrench 7/16 in To connect power/communication box to mounting plates.
Wrench & socket 9/16 in To connect mounting plates to forklift carriage.
USB Type “A” to Type “B” Cable 6 ft min Use with laptop for access to Revolution software for diagnostics,
calibration and displayed weight.
Level NA To perform angle zero calibration.
Fish tape 6 ft min Route power cable to forklift battery.
Crimping tool NA Battery connections.
Table 2-1. Recommended Tools for Unpacking and Installation of the CLS-M
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Page 9
2.3 Unpacking
Hardware
component
boxes
Note
The CLS is shipped upright on a sealed pallet with one or two scales per pallet, as shown in Figure 2-1.
Figure 2-1. CLS-M Packaging
Upon receipt of the shipping pallet, inspect it for any visible signs of damage. Immediately after unpacking,
visually inspect the contents to ensure all components are included and undamaged. The shipping pallet should
contain the following:
•One or two scale carriage assemblies with cover plate
•Hardware component boxes, which include:
• Two cleats with four bolts
• One coiled interface cable
• One power cable and hardware for battery connection
• One power/communication box
• One mounting kit for power/communication box with hardware
To ensure that all products received from the manufacturer are in good shape upon arrival, it is recommended
to fully inspect all contents and properly fill out the bill of lading.
If any parts were damaged in shipment, notify the shipper immediately.
2.3.1 Unpacking a One Scale Configuration
The scale is shipped in an upright position as illustrated in Figure 2-2. The upright position allows for ease of
installation. The power/communication box and accessories are located in a hardware component box.
1. Clip plastic band holding hardware component box in place and remove box.
2. Remove protective wood piece from the front of the scale.
3. Remove the front pallet support.
4. Clip the remaining plastic bands that are encircling the scale.
5. Remove the protective wood piece which protects the front of the scale.
Scale Base Installation 5
Page 10
Protective wood
covering
Wood shipping pallet
Hardware
component box
Step 1: Clip plastic band securing hardware
component box
Step 2: Remove protective wood covering
Hardware component box
plastic banding
Exploded view of components
Protective wood
covering
Front
pallet
Plastic banding securing
scale to pallet
Step 3: Remove front pallet support
Step 4: Clip remaining plastic bands
Step 5: Remove protective wood
Protective wood
covering
Scale is now ready for installation
Scale
Front pallet support
Figure 2-2. Scale Component Parts on Shipping Pallet for One Scale
6 Cargo Lift Scale Series
Page 11
2.3.2 Unpacking a Two Scale Configuration
WARNING
The scales are shipped in an upright position as illustrated in Figure 2-3. The upright position allows for ease of
installation. The power/communication box and accessories are located in a hardware component box.
When installing from a two scale configuration, complete all of steps for scale one before clipping plastic
bands securing second scale to the shipping pallet.
1. Clip top plastic bands.
2. Clip plastic band securing cardboard boxes to shipping pallet.
3. Remove the cardboard boxes.
4. Clip plastic bands from scale one.
5. Remove protective wood covering for scale one.
Scale one is ready for installation.
6. Once scale one has been installed, clip plastic bands from scale two.
7. Remove protective wood covering for scale two.
Scale two is now ready for installation.
Scale Base Installation 7
Page 12
Hardware
component boxes
Exploded view of components
Protective wood
covering
Wood shipping pallet
Plastic
banding
Step 1: Clip top plastic bands
Step 2: Clip plastic band to release hardware
component boxes
Step 3: Remove hardware component boxes
Step 4: Clip plastic bands from first scale
Step 5: Remove protective wood covering for first
Scale one is ready for installation.
DO NOT clip the plastic band from scale
two until scale one is installed
Step 6: Clip plastic bands from scale two.
Step 7: Remove protective wood covering for
second scale.
Scale two is ready for installation.
Protective wood
covering
Scale
Plastic
banding
Protective
wood
covering
Figure 2-3. Scale Component Parts on Shipping Pallet for Two Scales
8 Cargo Lift Scale Series
Page 13
2.4 Scale Base Installation
Top cleat
location
Shim bolt
hole location(s)
Anti-shift
centering pin
CAUTION
Note
WARNING
Note
Use the following steps to install the scale base to the forklift.
Figure 2-4. Anti-shift Centering Pin, Shim Bolts and Top Cleat Locations (One Scale Configuration Shown)
Verify that the shim bolts are flush with the back plate of the scale. Not doing so will place the entire scale
out of alignment when attaching it onto the forklift and will make it difficult to make final adjustments
once the scale is mounted onto the forklift.
1. Making sure the forks are removed from the forklift, move the forklift in close to the pallet and scale.
2. Ensure the anti-shift centering pin on the scale assembly is aligned with the center notch on the forklift
carriage.
The scale’s centering pin should be aligned with the middle notch of the forklift carriage. Verify that the
centering pin is adjusted so that the pin is located well within the center notch area of the carriage. The
centering pin should not touch the bottom of the notch on the original carriage, as this will cause side to side
tilting of the scale. The outside top cleats provide support to the scale assembly and the centering pin only
helps to position the scale on the forklift carriage. The centering pin should not bear any weight. If it does, the
use of a grinder to grind down the centering pin will help remedy that.
3. Tilt the mast forward slightly to catch the scale assembly.
4. Carefully and slowly raise the scale carriage slightly so the top cleats (cleat location shown in Figure 2-4)
5. Tilt the mast back to secure the connection and raise the scale to shoulder height.
6. Attach the bottom cleats to the bottom of the scale assembly (see Figure 2-5 for bottom cleat location), so
7. Torque the bottom cleat retaining bolts to 125 ft-lb.
8. Adjust the shim bolts so there is a minimal clearance between the bottom cleats and the scale carriage of
of the scale hook onto the forklift carriage. If they do not hook, push the scale toward the forklift as it is
being raised.
that the lip of the cleat is behind the scale carriage.
0.020-inch thickness. This can be measured by using the included feeler gauge.
Failure to properly torque the bottom plate retaining bolts may result in bodily harm or damage to
equipment.
Failure to adjust shim bolts to proper clearance of 0.020 inches may result in binding, poor accuracy or
improper fit of attachment to forklift.
Scale Base Installation 9
Page 14
Bottom cleat
retaining bolts
Shim bolts
Bottom cleat
Illustration shown is
with part of the
flexure removed to
show shim bolt
location.
Insert a feeler gauge to measure a
0.020-inch thickness between bottom
cleat and forklift carriage.
Scale carriage
Forklift carriage
3/16-inch gap max, for installation on
forklift to prevent side shifting.
9. Upon successful installation and calibration verification, seal the carriage j-box and load cell quick
disconnects for Weights and Measurements approval.
10 Cargo Lift Scale Series
Figure 2-5. Bottom Cleat Location and Assembly
Page 15
2.5 Connect the Coiled Interface Cable to J-Box
Loop Clamp Assembly
PN 167250
Bolt
Washer
Scale Cover
Assembly
Washer
Nut
Coiled Cable
Loop
Clamp
Loop Clamp Assembly
PN 150720
Used with Scale Cover
Assembly PN 97118
Used with Scale Cover
Assembly PN 162340
Note
Last notch open
Fork
Figure 2-7. Fork Attachment
Note
1. Loosen the bolt holding the cover to the scale assembly and remove cover. See Figure 2-6.
2. Assemble loop clamp kit to the coiled interface cable.
3. Route the coiled cable through clips on backside of carriage toward middle. For proper coiled cable
4. Push the coiled interface cable through the hole in the scale and connect it to the j-box. See Figure 2-6.
5. Position the scale cover assembly and the loop clamp assembly to the scale and secure with the bolt and
2.6 Install Forks onto Scale Assembly
The forks need to be installed onto the scale assembly.
1. Align a fork to the center of the scale
2. Lift the carriage slightly to set the fork,
3. Repeat process for other fork,
Figure 2-6. Connecting the Coiled Cable
routing, tighten clips. Set the other end of the cable aside until the power/communication box is installed
(See Section 3 on page 14).
washer.
After successful installation (Section 2.0 and Section 3.0) and calibration (Section 5.0), replace the cover on
the scale assembly and secure with bolt and washer.
assembly making sure it is over
the top of the assembly.
and then slide the fork to the side of the scale.
Let it stop in the 2nd notch from the end
and latch it in place.
sliding it the opposite direction on the scale.
For accurate weighing, it is best to leave forks at the second notch from the outside edge of the scale.
Scale Base Installation 11
Page 16
3.0 Cable Connections
Coiled interface
cable
Cable tie
Cable tie
Note
Figure 3-1. Coiled Interface Cable
3.1 Routing Coiled Interface Cable
Special care should be taken when routing the coiled interface cable. To ensure that the cable is installed properly
and away from situations that could cause it harm use the following steps:
1. The cable was connected to the load cell j-box during the scale installation. Retrieve the cable and route to
the mobile PC from the forklift scale.
2. Routing of cable will vary depending on forklift style. The preferred route for a single stage forklift is
through the center of the mast, up the front/right upright, to the area where the mobile PC is mounted.
Figure 3-2. Signal Cable Located Between the Scale and the Mobile PC
3. Secure with cable ties at the scale, at the top of the mast and several other locations to keep it securely in
place.
4. Slowly and carefully extend the mast to all positions to confirm that the cable isn’t pulled too tight or that
there are no pinch points along the way.
5. Check for proper signal cable clearance as the side shifter (if used), is moved back and forth.
When routing cables do not obstruct the view of OSHA labels on the forklift.
12 Cargo Lift Scale Series
Page 17
3.2 Pre-installed RS-232 Adapter Cable
RS-232 Adapter Cable
The RS-232 adapter cable (coiled cable to 9-pin RS-232) may be pre-installed
from the factory onto the mobile PC.
1. Ensure the mobile PC is OFF
2. Connect the coiled cable to RS-232 adapter cable, secure with tie wraps
to reduce accidental damage.
3.3 Connecting the Coiled Interface Cable/RS-232 Adapter Cable to Mobile PC
1. Ensure the mobile PC is off.
2. Connect female M16 connector to coiled cable.
3. Connect DB-9 connector to PC.
4. Attach cable to forklift cage with the wraps to reduce accidental damage.
3.4 Check Scale for Accuracy
For this application, the customer has pre-installed the Revolution software on the mobile PC. Follow the
instructions provided by the customer for accessing Revolution.
Cable Connections 13
Page 18
4.0 Revolution® Interface to CLS-M
Revolution is a tool to display weight, diagnostics and calibration (if required) of the CLS-M3 scale using a
®
Windows
based computer.
4.1 Connect Scale to Revolution
1. Open the Revolution program on the computer.
Figure 4-1. Revolution Screen at Open
2. Select File/New from the main toolbar.
3. Select the
4. Press
CLS-M Forklift option listed below for your model.
OK.
14 Cargo Lift Scale Series
Figure 4-2. Open Revolution to CLS-M3 Module
Page 19
5. Once selected, the main screen shown in Figure 4-3 is displayed.
A
B
C
D
1
Figure 4-3. Expanded Pitch Angle Selection
6. Go to Tools/Options (Figure 4-4 A) and select Settings (B), then choose the PC Comm Port (C).
7. Select available RS-232 Comm port.
8. Click
OK ( Figure 4-4 D).
Figure 4-4. Options Screen to Select Comm Port for USB
9. Select the connect icon from toolbar (Figure 4-5 A). A pop -up box comes up mo mentarily (Figure 4-6 A)
to indicate the computer is now indicated to the box.
10. If it comes up as
and that the mobile PC is turned on. Then select GO (Figure 4-6 on page 16 C) to connect.
Unable to Connect to Indicator (Figure 4-6 on page 16 B) verify the Comm Port is correct
Revolution® Interface to CLS-M 15
Page 20
Figure 4-5. Connect Revolution
B
A
A
B
C
Note
Figure 4-6. Connection Success/Failure
11. Press EZ Setup button (B).
4.2 Live Weight Data
The second tab is the Live Weight Data screen. This screen is used during calibration of the scale to verify the weight
values. The
1. Select the
Live Weight Data screen will only operate with the calibration switch in the closed position.
Live Weight Data tab (Figure 4-7).
Weight data packet screen shows output format of CLS-M3. Other displays include weight, pitch angle, roll
angle, cell 1 & 2mV. (Figure 4-7). This is the information that will be sent to the customer supplied hand-held
device when attached through Bluetooth.
To start streaming data check the auto refresh box. If not checked the refresh button will need to be selected
after each change of weight to load cell.
16 Cargo Lift Scale Series
Page 21
Figure 4-7. Revolution Live Weight Data screen.
A
B
C
D
E
F
G
H
Note
A. Weight Data Packet - output format/displays the output protocol of the CLS-M3.
B. Auto Refresh - when checked it starts continuous streaming of data in the weight data packet.
C. Zero - used to zero the scale.
D. Weight - displays value of weight on scale.
E. Pitch Angle - angle of the scale in a front to back direction.
F. Roll Angle - angle of the scale in a side to side direction.
G. Cell 1 mV (raw)
H. Cell 2 mV (raw)
4.3 Leveling Forklift Forks
1. Level the forks to 0° by placing a level on the forks and adjusting as required.
Carriage j-box will need to be in setup mode (See Section 5.3)
Turn off the forklift after leveling forks, high vibration from the running engine will cause inaccurate readings.
2. In the setup screen, press Zero Angle (Figure 4-8 A).
3. A pop-up appears as shown in (Figure 4-8 B), press
OK to close the pop-up box.
Revolution® Interface to CLS-M 17
Page 22
Figure 4-8. Zero Forks
A
B
Note
Forks should be level when testing calibration. A degree of tilt in either direction can cause errors in the use of
the scale.
18 Cargo Lift Scale Series
Page 23
4.4 Calibration
Note
A
B
C
Enter test weight value to
be used, minimum
suggested weight 500lbs.
A
Certified Test Weight used
during cell normalization
MUST be checked.
Future option, DO NOT
use at this time.
The carriage j-box will need to be in setup mode (See Section 5.3)
1. Select Standard Calibration (Figure 4-9 B)
2. Press
Next (Figure 4-9 C).
3. Enter test weight value to be used and press Next (Figure 4-10 A).
Certified Test Weight used during cell normalization must be checked.
Figure 4-9. Enter Calibration
Figure 4-10. Enter Test Weight Value
Revolution® Interface to CLS-M 19
Page 24
4. Corner Match Scale Calibration screen appears. Press Calibrate Zero (Figure 4-11 A).
Wait for Zero Calibrate
Complete to appear
before pressing next.
A
B
Note
Load Cell #1
(Left Hand)
Load Cell #2
(Right Hand)
5. When message in the lower left corner of message box reads
Zero Calibration Complete press Next
(Figure 4-11 B).
Figure 4-11. Calibrate Zero
6. Add known weight to load cell 1 (left hand load cell, see Figure 4-12).
7. Lift weight (allow it to stabilize if using hanging weight).
Always shut forklift off when calibrating, high vibration can cause inaccuracies.
Make sure to calibrate forks in correct order, or the calibration will not be successful.
20 Cargo Lift Scale Series
Figure 4-12. Load Cell #1 & #2
Page 25
8. Press Measure (Figure 4-13 A).
A
B
C
D
C
B
A
Figure 4-13. Load Cell Calibration
9. Load Cell #1 Status will read Success (Figure 4-13 B) and Load Cell #2 Measure will become available.
Repeat steps 9-11 for Load Cell #2.
10. When both load ce lls have been calibrated (status reads Success for both Cell #1 & #2, Figure 4-13 B) and
Normalization Successful message appears (Figure 4-13 C) press Next (Figure 4-13 D).
the
11. The message stating successful calibrated of the scale appears (Figure 4-14 A).
12. Press
Finish (Figure 4-14 B).
A message appears in the bottom of the frame
Getting New Calibration (Figure 4-14 C). When done the pop
up box will disappear and calibration is complete.
Figure 4-14. Finish Calibration
13. Place the calibration switch into the closed position (Figure 5-1), toward the left hand side of j-box when
standing in front of the scale (toward load cell #1).
Revolution® Interface to CLS-M 21
Page 26
4.4.1 Reading Data In Live Weight Screen
Value s
update
Weight value with weight applied to forks
Once calibration is complete, select the
Live Weight Data tab.
Figure 4-15. Revolution Live Weight Data Screen.
1. Place calibration switch into the closed position (Figure 5-1), toward the left hand side of j-box when
standing in front of the scale (toward load cell #1).
2. Test known weight amounts as specified in Section 4.1. When weight is on fork the value will appear in the
Weight box and the Weight Data Packet values will update.
3. If scale is weighing correctly, carefully disconnect USB and replace clear cover.
4. Swivel the cover plate back to the correct position and secure with screw.
5. Upon successful installation and calibration verification, seal the carriage j-box and load cell quick
disconnects for Weights and Measurements approval.
6. Re-install the scale cover plate (Section 2.0, Figure 2-6). The scale is now ready for use.
22 Cargo Lift Scale Series
Page 27
4.5 EZ Setup/Upload Unit Serial Number
Note
DO NOT change
the settings
under these
tabs. It will
cause system to
malfunction.
Note
Figure 4-16 appears with three tabs, Setup, Live Weight Data and Serial Number. Serial Number will be used for
entering the current serial number of the scale in the following sections.
All settings have been preset at the factory for communication with the hand-held device. DO NOT alter these
settings, it will cause communication failure with the hand-held device.
Figure 4-16. EZ Setup Screens - Setup
1. To check the serial number of the scale using Revolution, while in the EZ Setup mode, select the Serial
Number tab.
2. Select the
Get Current Serial Number button to get the current serial number.
3. If the j-box has been replaced and a new serial number must be entered, enter the new 6-digit serial number
from the forklift scale (A) and press the
Once the serial is download, a message
Download Serial Number button (B) to save the new serial number.
Serial Number sent to device is displayed on the screen and press OK
to accept that number.
The serial number of the scale is pre-loaded in the j-box at the factory, It does not need to be downloaded during
installation. If j-box is ever replaced (See Section 7.0 on page 42) this procedure will need to be repeated.
The serial number of the scale is located on the right side of carriage and also under the black cover plate on the
scale assembly.
The serial number (a 6 digit entry) screen typically displays 0 or the last serial number downloaded.
If installing a new serial number, un-install the existing Revolution software program prior to upgrading.
The upload and download of each configuration file is no longer required. The iQube2 j-box has default factory
settings to communicate with the CLS-M forklift scale.
Revolution® Interface to CLS-M 23
Page 28
4.6 Diagnostics
Note
Diagnostics
Power Supply:
Not Applicable to CLS M software
Slave Communications:
Not applicable to CLS M software
Diagnostics works in setup or normal operating mode.
1. On EZ Setup screen select Diagnostics.
Selecting Auto refresh will continuously display data communications for each screen.
Figure 4-17. Select Diagnostics
24 Cargo Lift Scale Series
Page 29
Excitation:
Not Applicable to CLS M software
Cell Connection:
Tests correct load cell cable connections
Scans each load cell to display connection issues
If one load cell connection error is found, will flash
between “No cell connection problems” and Scale:
SC1 Cell:1 or 2. While standing in front of the
forklift cell 1 is located on the left, cell 2 on the right.
Zero Reference:
Not Applicable to CLS M software
Overload Cell:
If error occurs displays mV level of the overloaded
load cell.
At 5000lbs the mV rating is 1.5
Revolution® Interface to CLS-M 25
Page 30
Cell drift:
Not Applicable to CLS M software
Underloaded Load cell:
If error occurs displays mV level of the underloaded
load cell.
At 5000lbs the mV rating is 1.5
Cell Noise:
Not Applicable to CLS M software
Unbalanced Cell:
Not Applicable to CLS M software
26 Cargo Lift Scale Series
Page 31
5.0 Calibration
Note
Direction of switch
for calibration
Front of forklift
ON
OFF
Calibration switch
cover plate
Calibration switch
Note
A
B
Note
When hanging weights from the forks make sure to note the weight of hanging device and add to test weight
value (Figure 5-4).
Make sure forks are level before beginning calibration (See Section 4.3).
Suggested test weight is 500lb minimum.
Always shut forklift off when calibrating, high vibration can cause inaccuracies.
When going through calibration steps, it is recommended that you do not use the back button, calibration may
not complete.
5.1 Carriage J-Box Calibration Mode
The load cell j-box must be placed in the calibration mode:
1. Remove the scale cover, if attached (Section 2.0, Fig Figure 2-6).
2. Remove one screw from the plate at the top of the j-box.
3. Swivel plate away from switch opening.
4. Place switch in the calibration position, away from coiled cable connection or toward the right hand side of
j-box when standing in front of the scale (load cell 2).
Figure 5-1. J-Box Calibration Switch Location
5.2 Leveling Forklift Forks
1. Level the forks to 0° by placing a level on the forks and adjusting as required.
Carriage j-box will need to be in setup mode (See Section 5.3)
Turn off the forklift after leveling forks, high vibration from the running engine will cause inaccurate readings.
2. In the setup screen, press Zero Angle (Fig 5-2 A).
3. A pop-up appears as shown in (Fig 5-2 B), press
OK to close pop-up box.
Forks should be level when testing calibration. A degree of tilt in either direction can cause errors in the use of
the scale.
Figure 5-2. Zero Forks
Calibration 27
Page 32
5.3 Calibrate Scale Using Revolution
A
B
C
Enter test weight value to be
used, minimum suggested
weight 500 lb. Add the chain
or hook weight value to test
weight.
A
Certified Test Weight used
during cell normalization
MUST be checked.
Future option, DO NOT use
at this time.
1. Connect computer to adapter on the coiled interface cable (see Section 3.3).
2. Level forks (see Section 5.2).
3. In set-up select
4. Select
5. Press
Standard Calibration (Figure 5-3 B)
Next (Figure 5-3 C).
Calibration (Figure 5-3 A).
6. Enter test weight value to be used and press Next (Figure 5-4 A).
Certified Test Weight used during cell normalization must be checked.
Figure 5-3. Enter Calibration
28 Cargo Lift Scale Series
Figure 5-4. Enter Test Weight Value
Page 33
7. Corner Match Scale Calibration screen appears. Press Calibrate Zero (Figure 5-5 A).
Wait for zero calibrate
complete to appear
before pressing next.
A
B
Note
Load Cell #1
(Left Hand)
Load Cell #2
(Right Hand)
8. When the message in the lower left corner of message box reads
Zero Calibration Complete press Next
(Figure 5-5 B).
Figure 5-5. Calibrate Zero
9. Add known weight to load cell 1 (left hand load cell, see Figure 5-6).
10. Lift weight (allow it to stabilize if using hanging weight).
If possible shut forklift off when calibrating, high vibration can cause inaccuracies.
Make sure to calibrate forks in correct order or the calibration will not be successful.
Figure 5-6. Load Cell #1 & #2
Calibration 29
Page 34
11. Press Measure (Figure 5-7 A).
A
B
C
D
C
B
A
Figure 5-7. Load Cell Calibration
12. Load Cell #1 status will read Success (Figure 5-7 B) and Load Cell #2 Measure will become available.
Repeat steps 9-11 for Load Cell #2.
13. When both load ce lls have been calibrated (status reads
Normalization Successful message appears (Figure 5-7 C) press Next (Figure 5-7 D).
the
14. A message that you have successfully calibrated the scale will appear (Figure 5-8 A) then press
Success for both Cell #1 & #2, Figure 5-7 B) and
Finish
(Figure 5-8 B).
A message appears in the bottom of the frame
Getting New Calibration (Figure 5-8 C). When done the pop
up box will disappear and calibration is complete.
Figure 5-8. Finish Calibration
15. Place calibration switch into the closed position (Figure 5-1), toward the left hand side of j-box when
standing in front of the scale (toward load cell #1).
30 Cargo Lift Scale Series
Page 35
5.3.1 Reading Data In Live Weight Screen
Value s
update
Weight value with weight applied to forks
Once calibration is complete select the
Live Weight Data screen.
Figure 5-9. Revolution Live Weight Data screen.
1. Place calibration switch into the closed position (Figure 5-1), toward the left hand side of j-box when
standing in front of the scale (toward load cell #1).
2. Check for accuracy as specified in Section 3.4. When weight is on fork the value will appear in the
Weight
box and the Weight Data Packet values will update.
3. If the scale is weighing correctly carefully disconnect USB and replace clear cover.
4. Swivel the cover plate back to the correct position and secure with screw.
5. Upon successful installation and calibration verification, seal the carriage j-box and load cell quick
disconnects for Weights and Measurements approval.
6. Re-install the scale cover plate (Section 2.0 Figure 2-6). Scale is now ready for use.
Calibration 31
Page 36
5.4 Weights and Measures Sealing
Weights and Measure seals
View from back of scale
Weights and Measures sealing location
Weights and Measures personnel will inspect the j-box for proper sealing once installed on the forklift. The j-box
must have the proper serial tag affixed to the box and lead wire sealing on the j-box.
Figure 5-10. Sealing the J-Box for Weights and Measures
32 Cargo Lift Scale Series
Page 37
6.0 Load Cell Replacement and Flexure Troubleshooting
WARNING
Note
This section describes procedures for replacing a load cell. The CLS-M Cargo Lift Scale uses Rice Lake’s load cell,
PN 125543.
The following instructions must be followed exactly to allow for seamless and easy load cell replacement.
Take all necessary safety precautions when installing or replacing the scale parts including wearing safety
shoes, protective eyewear, and using the proper tools.
6.1 Required Tools for Replacing a Load Cell
The following list of tools is necessary for replacing a load cell on the CLS-M scale. Ensure that you have these
tools handy.
Rice Lake Part # Item Description
96196 Modified box wrench
Crescent wrench
3/4" socket wrench, with extensions
ball-peen hammer
1-1/8" wrench for overload stop
Chisel
Allen wrench for overload stops
Torque wrench
Pry bar
Table 6-1. Required Tools for Replacing a Load Cell
Adequate light is necessary to change the load cell. Try to position the forklift close to a good source of natural
light or if not possible, have a good source of lighting available.
Load Cell Replacement and Flexure Troubleshooting 33
Page 38
6.2 Load Cell Replacement
#1 Upper Hex Nut
#2 Upper Hex Nut
#3 Spherical Washer Set
#4 Upper Block
#5 Spherical Washer Set
#6 Hex Nut
#7 Jam Nut
#8 Flexure Rod
#9 Jam Nut
#10 Load Cell
#11 Jam Nut
#12 Flexure Rod
#13 Jam Nut
#14 Hex Nut
#15 Spherical Washer Set
#16 Lower Block
#17 Spherical Washer Set
#18 Hex Nut
#19 Hex Nut
Modified
Wrench
A replacement parts kit is available (PN 97883), which contains all of the component parts shown in Figure 6-1.
34 Cargo Lift Scale Series
Figure 6-1. CLS-M Load Cell Assembly Parts Breakout
Page 39
Use the following steps to replace a load cell.
Slide forks to the middle of scale carriage
Note
1. Raise the forklift carriage just slightly for fork removal.
2. Slide the forks to the center of the carriage to allow for removal. Set forks aside.
Figure 6-2. Fork Removal
3. Raise the forklift carriage to a comfortable working height for the load cell replacement.
4. Remove the top hex nut (#1) with a socket wrench.
It’s okay if the load cell slightly rotates up against the front or back plate of the scale.
5. Loosen jam nut (#7) from the upper block using the special modified box wrench (PN 96196 - supplied
with load cell replacement kit) and shown in Figure 6-1.
6. Loosen jam nut (#13) from the lower block.
7. Remove the top hex nut (#2) and the top spherical washer set (#3).
Figure 6-3. Removal of Hex Nut (#1 of Parts Breakdown)
Load Cell Replacement and Flexure Troubleshooting 35
Page 40
Figure 6-4. Loosen and Remove Bottom Hex Nut (#18 and #19 on Parts Breakdown)
Note
Ensure flexure rod threads are free of
debris and paint by running a nut the
full distance of the rod.
It’s okay if the load cell slightly rotates up against the front or back plate of the scale.
8. Remove the bottom hex nuts (#18 and #19) and the bottom spherical washer set (#17).
9. Loosen the hex nut located under the upper block (#6).
10. Loosen the jam nut located on top of the load cell (#9).
11. Loosen the hex nut (#14) located on top of the lower block.
12. Loosen the hex nu t (# 11) on the lower side of the load cell.
13. Remove the bottom flexure rod (#12) and the top flexure rod (#8) sliding the remaining washer sets (#5
and #15) with it.
.
Figure 6-5. Remove Flexure Rod with Nuts and Washers
14. Check the flexure rod threads for smooth operation by running a nut the full distance of the rod, making
sure it does not get stuck anywhere along the way. If so, clean off any paint using a wire brush and oil.
15. Oil the spherical washers using a standard machine shop oil.
16. Disconnect the load cell cable from the junction box.
17. Loosen cable clips and remove the load cell.
36 Cargo Lift Scale Series
Page 41
Figure 6-6. Load Cell Cable Clips
Detach load cell
clip from back plate
of scale using a
large screwdriver.
Load cell cable should face
towards the center of the scale.
18. Position a new load cell with its cable facing towards the center and opening of the S-beam facing the
flexure's.
Figure 6-7. Load Cell
Load Cell Replacement and Flexure Troubleshooting 37
Page 42
19. Install the top and bottom flexure rod with hardware, ensuring that the flexure rod be oriented with the
Short threads
facing nearest
the load cell.
Use chisel to hold load
cell straight.
short thread of the rod facing nearest the load cell.
Figure 6-8. Installing Flexure into Scale
20. Insert the load cell and thread flexure rods into top and bottom of the load cell making sure the appropriate
hex nuts, jam nuts, and spherical washers are in the correct order per Figure 6-1 on page 34.
21. Screw in the rod and tighten jam nut but, leave approximately two threads exposed outside of the jam nut.
Do both the top and bottom of the load cell.
22. Use hex nuts to position the load cell in the center of the mounting blocks with an equal amount of flexure
rod on the top and bottom of the load cell.
23. Tighten the jam nuts on the top and bottom of the load cell, making sure they are tight, and load cell is
completely vertical with the scale. To accomplish th is, you can use a pry bar or chisel to hold the cell
straight as illustrated in Figure 6-9.
Figure 6-9. Use Chisel to Hold the Load Cell in Straight
24. Install the spherical washer set and hex nut on the bottom flexure rod, ensuring that the fat washer is
mounted towards the mounting block.
38 Cargo Lift Scale Series
Page 43
Figure 6-10. Install Spherical Washer Set
Insert the flat-blade
screwdriver here to
help center the flexure
rod.
25. Install a flat-blade d screwdriver in the upper mounting block between the hole and the flexure rod, forcing
the flexure rod in the same direction of the flexures.
Figure 6-11. Centering the Flexure Rod
26. Use a pry bar or chisel to hold the load cell (bottom half of the cell), straight while using a torque wrench
to tighten the bottom hex nut on the lower mounting block to 110 ft-lb. Install the other hex nut on the
bottom of the flexure rod and torque it to 110 ft-lb.
Figure 6-12. Centering the Load Cell Using a Chisel
Load Cell Replacement and Flexure Troubleshooting 39
Page 44
Figure 6-13. Tightening the Lower Hex Nut
27. Use the special modified box wrench to tighten the jam nut (#13) on the lower block.
28. Remove the flat-bladed screwdriver as used in Step 25 and inspect the flexure rod. The flexure rod needs to
be in the center of the hole. If it is not, use a hammer and an angled diamond chisel to hit the bottom
mounting plate and spherical washer set to adjust it to center.
29. Install the spherical washer set (#3) and hex nut (#2) on the top of the upper block.
30. Connect the load cell cable to the junction box at this time.
31. Torque the hex nut (#2) on the upper mounting block until you see 100 lb on the weight display. Tighten
the lower hex nut (#6) below the upper mounting block using the modified box wrench and try to get the
display as close to zero as possible.
32. Torque the top hex nut (#1) with a torque wrench to 110 ft-lb. Use a pry bar or chisel to ensure the load cell
stays centered while tightening and doesn’t touch the sides of front or back plate
33. Install the final hex nu t on the top mounting plate and torque to 11 0 ft-lb. Use a pry bar or chisel to keep
the load cell centered.
34. Tighten the jam nut on the lower mounting block assembly.
35. Exercise the scale, heel to toe, by placing a weight (1000 lb) on the heel, then the toe to check if the
assembly was installed correctly. Do this for both sides. If the weight is off, check assemblies.
36. Place a weight in the center of the fork and check side to side values. If they are equal, you are done.
37. Calibrate the load cells (See Section 5.0 on page 46).
40 Cargo Lift Scale Series
Page 45
6.3 Forklift Flexure Troubleshooting - 28" and 34" Models
4.12
3.00
4X .25
For Part Number 92828
The forklift flexure is designed to protect the load cell from damage in the forklift environment.
Use the following steps if the forklift scale is out of tolerance or unable to return to zero on a consistent basis.
1. Check for debris within the scale or between the scale carriage.
2. Check for proper spacing of the jam nuts at 0.02".
3. Check the dimensions of the flexure for damage. There should be a +/-0.03" tolerance to the drawing
shown below for height and width.
Figure 6-14. Flexure Chassis
Load Cell Replacement and Flexure Troubleshooting 41
Page 46
7.0 iQube2® J-Box
Bolt and washer securing
cover to scale
Cover plate
Note
Coiled Cable
Connector
Load Cell Cable
Connector
Load Cell Cable
Connector
Breather Vent
Calibration Switch Access
Sealing Point
Figure 7-2. iQube2 J-Box
The iQube2 j-box designed for use with the Rice Lake CLS-M series forklift scales and is a replacement for the
j-box used on early models of the scale. Load cell connectors have been updated to improve serviceability.
7.1 iQube2 J-Box Replacement
The j-box is located between the front and back panel of the scale and is covered by a metal cover plate on the top
of the scale.
1. Turn scale power off on the Communication/Power box.
2. Remove the bolt that holds the cover plate in place, which conceals the junction box.
3. Remove the cover plate and set aside.
4. Unplug power cable.
5. Lift the forklift to a comfortable working height.
6. Remove the two screws securing the j-box to the scale, using a #4 metric Allen wrench, to remove existing
j-box from scale carriage.
7. Remove the coiled interface cable from the junction box.
8. Disconnect the load cell cables.
9. Remove automotive quick
connects from load cell cables.
10. Strip wires for connection to the
new load cell connectors. See
Figure 7-3.
11. Follow the instructions on the
packaging for Turk connector, PN
BS-8157-0/P69, for inserting
wires.
12. Wire the load cell 5-pin male
connector to the following color
codes Table 7-1 and Figure 7-3.
Note the orientation of the raised
diamond in Figure 7-3. Use the
supplied tool in the rectangular
tool slot to lock wires down.
Figure 7-1. Remove Cover Plate
Steps 9-14 are only required when upgrading the original j-box to an iQube2. If replacing an iQube2 with another
iQube2 skip to step 15.
42 Cargo Lift Scale Series
Page 47
Load Cell 5 Pin Male Connector Wiring
Load Cell Stripping Wiring Load Cell Wiring
Two Threads Visible
Pin # Wire Color Function
1 Green +SIG
2 White -SIG
3Red +EXC
4 Black -EXC
5 Yellow Ground
Table 7-1. Load Cell Wiring
Figure 7-3. Load Cell Wiring
13. Add blue Loctite®1 425 to the two contact points as indicated in Figure 7-3.
14. Attach the load cell cables to the bottom two connectors on the junction box.
• Apply Loctite.
• Hand tighten until the connection is snug, plus another 1/4 turn. Only two threads should be visible.
Figure 7-4. Connect Load Cell Cable to J-Box
15. Attach the home run cable to the top side connector.
16. Install the iQube2 j-box into the forklift scale, using Loctite on the mounting screws.
17. Open the calibration access switch cover on the j-box, set switch to the
18. Plug in the power cable, and turn on the communication power box.
19. Calibrate the unit using Revolution software.
20. Connect the load cell cables to each side.
21. Connect the coiled interface cable to the top of the j-box.
22. Align the iQube2 j-box with the bolt holes in the scale and use an Allen wrench to tighten.
23. Place the cover plate in place and secure with a bolt and washer, and seal the unit.
1. Locktite® is a registered trademark of Henkel Technologies.
On position.
iQube2® J-Box 43
Page 48
7.2 Download the Serial Number to the J-Box
Serial number tab
A
B
Note
1. To download the serial number of the scale using Revolution while in the EZ Setup mode, select the Serial
Number tab.
2. Enter the new six-digit serial number from the forklift scale (A) and press the
button (B) to save the new serial number.
Figure 7-5. Serial Number Setup Screen
Download Serial Number
3. Once the serial number is download, a message Serial Number sent to device is displayed on the screen.
OK to accept that number.
Press
The serial number of the scale is located on the right side of the carriage and also under the black cover plate on
the scale assembly.
The serial number (a six-digit entry) screen typically displays 0 or the last serial number downloaded.
The upload and download of each configuration file is no longer required. The iQube2 junction box has default
factory settings to communicate with the CLS forklift scale.
44 Cargo Lift Scale Series
Page 49
7.3 iQube2 PCB Board Assembly Replacement
TVS11
MH1
J1
R60
TP19
R10
U9
TVS1
S1
U23
X3
LED1
U18
F2
U32
L5
R56
U8
F1
U33
U6
JP2
C51
C53
C45
U30
U31
R75
C39
C54
R19
R98
R57
C11
C119
C55
TVS8
X2
C52
C56
MH3
C46
LED3
JP3
R9
C41
R58
TP25
D18
C62
U28
C110
R74
C13
C36
C89
U4
D16
IC1
R18
C82
U29
C61
C40
C118
D14
C72
J5
U5
TP26
LED2
C71
C44
J2
X1
U13
D19
C34
U19
U22
C99
C60
MH4
C59
R54
TP28
C63
C12
C37
R89
C48
C35
TP23
R61
TP24
TVS9
C117
VR3
U25
U20
C50
C73
C14
TVS10
R62
MH2
C28
C64
C30
C29
JP1
C31
C70
TP22
TP4
C38
TP21
TP9
D22
R88
TP10
TP11
TP12
TP13
TP8
TP7
TP6
TP5
TP3
U14
TP16
TP15
TP14
TP17
TP18
TP20
FW1
Vx.xx
J3
D7
Q1
C115
C43
C120
L2
U15
C15
U16
C77
LB2
C98
R68
R67
C121
D21
J4
RICE LAKE
Pb
VR5
C66
C75
C42
D20
D8
R77
R87
R31
R93
R86
R95
R91
R34
R36
R72
R37
R92
R35
R85
R30
R90
R38
R16
R65
R4
R15
R29
R109
R110
R59
R27
R22
R28
R69
R66
R70
R64
XF1
TVS4
TVS3
C19
C18
L1
C68
C69
TVS2
SETUP
CGND
EXC
ALIVE
USB
GND
RS232_RX
SIG
PU
2+
RS232_TX
DGND
JTAG
CGND
2-
SIG
1+-1-
2+
-
1+
PWR
EXC
J1
J2
J3
Coiled cable
connection
Left load cell
connection
Right load cell
connection
1. Remove j-box from the scale carriage. See Section 7.0 on page 42.
2. Disconnect load cell and coiled cable connectors
3. Loosen four screws to remove front cover of j-box.
4. Disconnect JST connectors for load cells and coiled cable.
5. Remove PCB board assembly.
6. Install new PCB board assembly and install screws using blue Loctite
7. Connect coiled cable JST connector to J1.
8. Connect left load cell cable JST connector to J2.
9. Connect right load cell cable JST connector to J3.
10. Replace cover and secure with four screws, Locktite not required.
®
.
Figure 7-6. PCB Board Assembly
iQube2® J-Box 45
Page 50
7.4 iQube 2.3 Cross References
Note
When identifying the correct j-box cross referenced part number, please provide the serial number of the scale so
that the Rice Lake Weighing Systems sales and service departments can track it to the correct top level part number
sold.
To verify the correct j-box has been received, use Table 7-2, the iQube 2.3 j-box part number reference table.
The kit part number includes the appropriate load cell and cable adapters required to upgrade your unit.
This manual references the part numbers 156294 only.
28" Forklift Carriage
Top Level Fork Lift PN Indicator iQube 2.3 Kit PN iQube 2.3 J-Box PN
111033 420 Wired 167345 167344
111034 420 Wireless 167416, 167344
111035 920i Wired Upgrade not available 121014
111036 920i Wireless 121014
34" Forklift Carriage
Top Level Fork Lift PN Indicator iQube 2.3 Kit PN iQube 2.3 J-Box PN
96339 420 Wired 167345 167344
96340 420 Wireless 167344
96341 920i Wired Upgrade not availabl 121014
96342 920i Wireless 121014
130822 420 Wired 167356 167261
130823 420 Wireless 167261
130824 920i Wired Upgrade not available 130826
130825 920i Wireless 130826
SPX or SO WO 420 ABF 167345 167344
120911 420 ABF 167356 167261
161964 420 ABF 167341 167261
125277 CLS-M 167340 164071
153539 CLS-M 167340 164071
151803 CLS-420 167356 167261
132414 CLS-M2 167340 164071
156294 CLS-M3 167340 164071
164649 CLS-420 167341 167261
162279 CLS-420 167341 167261
38" Forklift Carriage
Top Level Fork Lift PN Indicator iQube 2.3 Kit PN iQube 2.3 J-Box PN
111038 420 Wired 167407
111039 420 Wireless 167407
111040 920i Wired Upgrade not available 121366
111041 920i Wireless Upgrade not available 121366
151506 420 Wireless 167407
151490 920i Wireless Upgrade not available 121366
Table 7-2. iQube 2.3 Cross References
46 Cargo Lift Scale Series
Page 51
8.0 Appendix
17
2
5
4
3
11
12
13
14
16
13
15
10
9
1
7
11
12
13
14
13
15
Used with Scale Cover
Assembly PN 162340
Used with Scale Cover
Assembly PN 97118
18
8.1 Parts Breakout
Figure 8-1. CLS-M3 Scale Assembly
Item No. Part No. Item Description Qty
156294 Scale, CLS-M3 Ref
1 125395 Cable Assy, Coiled 5x18AWG 1
2 153296 Adapter 1
3 127009 Screw, Cap 5/8-11NC 1
4 111731 Washer, Lock 5/8 Regular 1
5 162340 Scale Cover Assembly with Decal (2015+) 1
97118 Scale Cover Assembly 1
7 164071 iQube2 J-Box Assembly with Turk Connectors 1
9 125368 Scale, Cargo Lift (See Fig 8-2) 1
10 99191 Decal, Rice Lake 1
11 167250 Kit, Loop Clamp, Coiled Cable Assy (Inc 12-15) 1
150720 Kit, Loop Clamp, Coiled Cable Assy (Inc 12-16) 1
12 126980 Screw Machine 10-32 x 1/2 1
13 15141 Washer, Plain STD No 10 2
14 150719 Clamp, Loop One Hole 1/4” 1
15 14633 Nut, Lock 10-32NF Hex 1
16 130928 Bracket, CLS (inc with PN 150720 only) 1
17 125649 Hex Socket Cap Screw 10-32 x 1 SST 2
18 92831 Centering Pin 1
Appendix 47
Page 52
3
1 PER SIDE
15
5
12
14
7
9
10
6
11
1
12
12
2
10
8
5
11
11
10
6
1
11
13
8
2
4
14
14
4
13
12
7
7
5
16
5
3
9C
9B
9A
Note: Torque 5/8-11 Bolts to 150 ft-lbs (Typ)
Item
No.
1 15198 Washer, Spherical.53x1.12 8
2 92822 Bolt, 1-8NCx2-3/8 Gr 5 2
3 92812 Screw, Cap 3/8-16NCx1/2 2
4 126770 Cleat, Bottom, Thick for use on worn carraiges 2
5 92828 Flexure, 1x3x4.12 17-4PH 4
6 92827 Flexure Rod, 1/2-20x6.13 4
7 15061 Screw, Cap 1/2-13NCx1-1/2 16
8 14701 Nut, Jam 1-8NC HEX Steel 2
9 125543 Load Cell, With Quick Connect 2
9A 166623 Load Cell, with Turk Screw Connectors (inc 9B & 9C) 2
9B 166756 Conn,M12 5 Pin Male Field 1
9C 96198 Load Cell,SBM RL20000 FLS 1
10 14665 Nut, Jam 1/2-20NF HEX SST 8
11 109958 Nut, Full 1/2-20NF HEX SST 12
12 14688 Nut, Jam 3/4-16NF HEX SST 4
13 92810 Screw, Cap 5/8-11NCx2-1/2 4
14 92814 Screw, Set 3/4-16NFx2.406 4
15 125367 WLDT, Assy Back Plate 34in 1
16 125547 WLDT, Front Plate 34in 1
Part No. Item Description Qty
125368 Scale Section Assy 34
Figure 8-2. CLS-M3 Scale Parts
48 Cargo Lift Scale Series
Page 53
9
10
8
11
4
5
12
13
14
15
1
3
2
6
7
Included with
cable assemblies
Included with
cable assemblies
Figure 8-3. iQube2 J-Box Assembly, PN 164071
Item
No.
Part No. Item Description Qty.
1 162378 Enclosure Assembly 1
2 163767 Data Receptacle Cable Assembly 1
3 163766 Load Cell Cable Receptacle Assembly 2
4 164598 Breather Vent 1
5 88734 Nut, Breather Vent Thread 1
6 167999 J-Box PCB Assembly 1
7 14839 Screw, 6-32NC x 1/4 4
8 162383 Cover Assembly 1
9 163764 Gasket, Assembly Cover 1
10 164070 Gasket, Access Cover 1
11 100968 CR-FHMS 0.164-32 x 0.5 x 0.5-N-SST 4
12 163765 Gasket, Access Cover 1
13 162384 Cover Plate, Access Hole 1
14 75062 Sealing Washer, #8 3
15 30623 Screw, 8-32NC x 7/16 3
16 52342 Label
1
Appendix 49
Page 54
Supplied
w/ J-Box
10
13
3
2
19
9
5
16
14
18
15
20
23
17
8
1
3
13
10
6
18
15
11
22
4
7
21
10
12
24
THIS PAGE
FOR
REFERENCE
ONLY
.
Item
No
Part No. Item Description Qty
1 132726
Board,CLS-M J-Box Rev C
1
2 125640
Enclosure,Machined CLS-M
1
3 19528
Post Only,Slotted Black
2
4
Seal, Cable Gland
Ref
5 75062
Washer, Bonded Sealing SST
2
6 128022
Vent,Breather Sealed
1
7 125650
O-Ring,Buna N 70 160
1
8 14839
Screw
Ref
9 125564
Cover, J-Box Set-Up Switch
1
10
Cable Gland
Ref
11
Screw
Ref
12 100968
Screw, Mach 8-32NC x ½
4
13 125376
Seal, Cable Gland
2
14 125942
Gasket,Rubber CLS-M
2
15 42640
Screw,Mach 1/4-28NF X ¼
2
16 81220 Screw, Mach 6-32NCx1/2 2
17 125559
Cable Assy,CLS-M Carriage
2
18 31546
Washer,Lock 1/4 Internal
2
19 125565
Gasket, Access Port Cover
1
20 126167
Wire,Ground 4 Inch
1
21 125494
Plate,Adapter CLS-M
1
22
Washer
Ref
23 52342
Label
1
24 125649
Screw, Cap 10-32 x 1 SST
2
Item
No
Part No. Item Description Qty
Figure 8-4. J-Box Assembly, PN 159589
50 Cargo Lift Scale Series
Page 55
8.2 Troubleshooting Table
Symptom Possible Cause Action
Scale displaying negative weight Forks are resting (even slightly) on the floor. Lift forks up off floor.
Scale reading high against test
weight.
Scale reading low against test
weight.
Scale not returning to zero (0) Forks are touching the ground. Lift forks off ground, press the Zero key.
Will not display small weight
values
Unstable weight Power connections faulty, low battery Check battery power cable.
Scale reading incorrect weight
value
Material, like wood debris, between the scale
and the forklift carriage.
Material, like wood debris, between the front
and back scale plates.
Centering pin touching the forklift carriage,
causing it to teeter back and forth.
Bottom cleats not adjusted properly or loose. Adjust to proper gap using jam nuts, 0.02”
If all these steps do not resolve your issue, check the following,
J-box error Open j-box and look for obvious damage
Load cell errors Test mV/v levels, at 1.5 mV per 1,000 lb,
Calibration is required
Zero key has been pressed with a negative
weight reading, while forks are on the floor.
Material, like wood debris, between the scale
and the forklift carriage.
Material, like wood debris, between the front
and back scale plates.
Centering pin touching the forklift carriage,
causing it to teeter back and forth.
Bottom cleats not adjusted properly or loose. Adjust to proper gap using jam nuts, 0.02"
If all these steps do not resolve your issue, check the following
J-box error Open j-box and look for obvious damage.
Load cell errors Test mV/v levels, at 1.5 mV per 1,000 lb,
Calibration is required Calibrate the scale using Revolution.
Material, like wood debris, between the scale
and the forklift carriage.
Material, like wood debris, between the front
and back scale plates.
Centering pin touching the forklift carriage,
causing it to teeter back and forth.
Bottom cleats not adjusted properly or loose. Adjust to proper gap using jam nuts, 0.02"
Scale is in motion, it won’t zero if the forklift is
moving:
• Forks moving up and down
• Forklift is being driven
If all these steps do not resolve your issue, check the following,
J-box error Open j-box and look for obvious damage.
Load cell errors Test mV/v levels, at 1.5 mV per 1,000 lb,
Digital filter sensitivity is too high. Using Revolution:
Tare is enabled At stable zero weight, press the TAR E key
Remove debris.
Remove debris.
Adjust scale carriage, centering pin should
not touch on sides and bottom.
test at 350 ohms
Calibrate the scale using Revolution
Lift forks off ground, press the Zero key
Remove debris
Remove debris
Adjust scale carriage, centering pin should
not touch on sides and bottom.
test at 350 ohms
Remove debris
Remove debris
Adjust scale carriage, centering pin should
not touch on sides and bottom.
Bring forklift to a complete stop and ensure
forks are still.
test at 350 ohms.
scales menu/scales #1/filtering
change the digital filitering sensitivity to
light and change digital filter threshold
to 10°.
Check for low battery voltage.
to return to normal weighing mode.
TM
Appendix 51
Page 56
Symptom Possible Cause Action
Intermittent weight readings,
weight reading high and low.
Weight on forks, no displayed
weight.
Material, like wood debris, between the scale
and the forklift carriage.
Material, like wood debris, between the front
and back scale plates.
Centering pin touching the forklift carriage,
causing it to teeter back and forth.
Bottom cleats not adjusted properly. Adjust to proper gap using jam nuts, 0.02"
Check alignment of load cells. Adjust load cells.
Low forklift battery Charge forklift battery, disconnect power
Check coiled cable for loose connections &
wear.
If all these steps do not resolve your issue, check the following,
Load cell connections on j-box Securely fasten connections.
J-box error Open j-box and look for obvious damage.
Load cell errors Test mV/v levels, at 1.5 mV per 1,000 lb,
Calibration is required. Calibrate the scale using Revolution.
Material, like wood debris, between the scale
and the forklift carriage.
Material, like wood debris, between the front
and back scale plates.
Centering pin touching the forklift carriage,
causing it to teeter back and forth.
Bottom cleats not adjusted properly. Adjust to proper gap using jam nuts, 0.02"
Low forklift battery. Charge forklift battery.
Coiled cable error Check coiled cable connections wand
If all these steps do not resolve your issue, check the following,
J-box sealing switch is in calibration mode. Move switch to weighing mode.
Load cell connections on j-box loose. Securely fasten connections.
J-box error Open j-box and look for obvious damage.
Load cell errors Test mV/v levels, at 1.5 mV per 1,000 lb,
Calibration is required. Calibrate the scale using Revolution.
Remove debris
Remove debris
Adjust scale carriage, centering pin should
not touch on sides and bottom.
prior to charging.
Fasten coiled cable connections.
Replace coiled cable, if damaged.
test ohms using Revolution/Live Weight
Data/Cell 1 & 2 MV
Remove debris
Remove debris
Adjust scale carriage, centering pin should
not touch on sides and bottom.
wear and tear.
test ohms.
52 Cargo Lift Scale Series
Page 57
Symptom Possible Cause Action
TVS11
MH1
J1
R60
TP19
R10
U9
TVS1
S1
U23
X3
LED1
U18
F2
U32
L5
R56
U8
F1
U33
U6
JP2
C51
C53
C45
U30
U31
R75
C39
C54
R19
R98
R57
C11
C119
C55
TVS8
X2
C52
C56
MH3
C46
LED3
JP3
R9
C41
R58
TP25
D18
C62
U28
C110
R74
C13
C36
C89
U4
D16
IC1
R18
C82
U29
C61
C40
C118
D14
C72
J5
U5
TP26
LED2
C71
C44
J2
X1
U13
D19
C34
U19
U22
C99
C60
MH4
C59
R54
TP28
C63
C12
C37
R89
C48
C35
TP23
R61
TP24
TVS9
C117
VR3
U25
U20
C50
C73
C14
TVS10
R62
MH2
C28
C64
C30
C29
JP1
C31
C70
TP22
TP4
C38
TP21
TP9
D22
R88
TP10
TP11
TP12
TP13
TP8
TP7
TP6
TP5
TP3
U14
TP16
TP15
TP14
TP17
TP18
TP20
FW1
Vx.xx
J3
D7
Q1
C115
C43
C120
L2
U15
C15
U16
C77
LB2
C98
R68
R67
C121
D21
J4
RICE LAKE
Pb
VR5
C66
C75
C42
D20
D8
R77
R87
R31
R93
R86
R95
R91
R34
R36
R72
R37
R92
R35
R85
R30
R90
R38
R16
R65
R4
R15
R29
R109
R110
R59
R27
R22
R28
R69
R66
R70
R64
XF1
TVS4
TVS3
C19
C18
L1
C68
C69
TVS2
SETUP
CGND
EXC
ALIVE
USB
GND
RS232_RX
SIG
PU
2+
RS232_TX
DGND
JTAG
CGND
2-
SIG
1+-1-
2+
-
1+
PWR
EXC
USB traffic from type A
micro connector
D20 - PC board
power from
coiled cable
LED 2 - Heartbeat
through RS-232/
Isolation chip
LED 3 - Processor
UART activity
D8 - Micro
processor
heart beat
VIRTUi2 displays INVALID. Calibration switch in open position
J-box error check wiring connections
Check load cell wires
Check excitation on j-box at 4.1.
VIRTUi2 weight display is blank. No power. Turn on COMPOW
Scale carriage is not fitting
securely on forklift during
installation.
May have to use electric grinder to grind
down the centering pin on the forklift scale or
center slot on forklift.
May have to grind or torch down the area
where the top cleats of the forklift scale are
mounted.
May have to grind or torch side of forklift
carriage due to previously installed side shift
protection method.
Loose screws on j-box Apply loctite 242 or 243 for greasy
Move calibrationswitch to closed position.
Press reset in VIRTUi2.
Correct wiring.
Change j-box.
Check
Discuss with local terminal manager to
determine if scale dealer is to perform this
chargeable service.
enviroments, to screws and tighten.
8.3 Troubleshooting iQube2 LEDs
Figure 8-5. Troubleshooting iQube2 PCB Assembly LEDs (PN 162508)
Appendix 53
Page 58
54 Cargo Lift Scale Series
Page 59
Page 60
230 W. Coleman St. • Rice Lake, WI 54868 • USA
U.S. 800-472-6703 • Canada/Mexico 800-321-6703 • International 715-234-9171 • Europe +31 (0)26 472 1319
www.ricelake.com www.ricelake.mx www.ricelake.eu www.ricelake.co.in
Rice Lake Weighing Systems is an ISO 9001 registered company.
© Rice Lake Weighing Systems Specifications subject to change without notice.
07/2016 PN 157393 Rev E
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