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| Illustration 1 | g00988242 |
The previous chart shows the menus for setup mode that are available. These menus are used for configuring the Payload Control System PCS. The first menu contains the Operator Setup. You will then be prompted for a password. After you have entered the password, you have access to the Owner Setup menu.
Some initial steps are needed in order to operate the PCS. This procedure should be done before any other activity takes place.
When you select a function of the menu, the title of the menu is shown for one time on the display. The current selection is then shown on the top line.
All of the options can be consecutively displayed by pressing the "SCROLL" key. Only the current selected menu will be underlined.
Press the "SCROLL" key in order to select a new option. Continue to press the "SCROLL" key until the desired option is shown on the display. Then press the "STORE" key. The new selection will be displayed and the new selection will be underlined. The selection will be displayed for one second. The system will then advance to the next function.
Pressing the "NEXT FUNCTN" key will advance to the next menu. This is only possible if the menu is on the current selection.
Pressing the "STORE" key will underline the current selection if the menu is not on the current selection. Press the "CLEAR" key in order to return the system to the weigh mode. Pressing the "NEXT FUNCTN" key will advance to the next menu.
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| Illustration 2 | g00989237 |
When the system is in the weigh mode, the menu for setup is accessed by pressing the "NEXT FUNCTN" key or the "SETUP" key. All of the setups for the operator are stored in permanent memory. The setups will remain active until the setups are changed.
Identification of the Operator
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| Illustration 3 | g00582952 |
This is an optional mode for numeric input. This allows the operator to enter a five digit number for identification. The number can be from 0 through 99999. This number is logged with the data for the truck. This number is also shown on the printouts for the truck.
This function can be disabled and enabled. This can be accomplished from the owner setup menu. The mode for entering the identification number of the operator is automatically entered when the system is turned ON or when the setup for the operator is entered. This is only true if the function for identification of the operator is enabled.
Setting the Identification Number of the Operator
- Press the "SETUP" key or the "NEXT FUNCTN" key when you are in the weigh mode.
- The menu "OPERATOR ID" will be shown on the display. The current selection will be shown on the display and the current selection will be underlined.
- Use the keypad in order to enter the identification number of the operator. Press the "STORE" key.
- The display will now change to the "Units Menu".
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| Illustration 4 | g00582993 |
This menu allows the selection of the units for the display of the weight. The units can be displayed in "U.S Tons", "Metric Tons", or LBS x 1000. The selection also sets the units for the printer.
- Place the system in Weigh mode. Press the "NEXT FUNCTN" key. Press this key until the "UNITS MENU" is shown on the top line of the display.
- The display will show the current units. The current units will be underlined.
- Press the "SCROLL" key in order to cycle between the units.
- Press the "STORE" key in order to select the units that are being displayed. The selected units are now underlined.
- The display now changes to the next menu. The next menu is the "Language Menu".
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| Illustration 5 | g00582996 |
This menu selects the language of the display and the language of the printer. The default language is English. The following languages are also available. German, French, Portuguese, Italian, Spanish, Swedish and Norwegian
- Place the system in Weigh mode. Press the "NEXT FUNCTN" key. The "LANGUAGE MENU" will be shown on the top line of the display.
- The current language will be shown on the display. The current language will be underlined.
- Press the "SCROLL" key in order to cycle between the different languages.
- Press the "STORE" key in order to select the language that is displayed. The selected language is now underlined.
- The display will now change to the menu for setting the scroll speed of the display.
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| Illustration 6 | g00583147 |
Five different speeds are available.
- Place the system in the weigh mode. Press the "NEXT FUNCTN" key. Press this key until "SCROLL SPEED MENU" is shown on the top line of the display.
- The display will show the current scroll speed. The speed will be underlined.
- Press the "SCROLL" key in order to cycle between speeds.
- Press the "STORE" key in order to select a scroll speed. The selected scroll speed is now underlined.
- The display will now change to the next menu. The next menu is "Pword". This menu is the start of the "Owner Setup Procedure".
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| Illustration 7 | g00989249 |
This menu is located at the end of the menu for the setup of the operator. This menu is protected by a password. This menu contains functions for setup that will be set for one time. This is usually performed when the machine is delivered. The one exception would be the setting of the time and the date. This is the first option after entering the password.
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| Illustration 8 | g00583259 |
You need to enter a password in order to access the setup of the owner. The default password is 12345. This is the password that is shipped from the factory. The "Change Password" menu can be used in order to change the password.
Note: The password can be changed by using the "Change Password" menu. This menu is located at the end of the procedure for "Owner Setup".
- Place the system in weigh mode. Press the "NEXT FUNCTN" key until "PWORD" is shown on the top line of the display. "PWORD" will exit if the numbers are not pressed within five seconds.
- Enter the password. This is needed in order to access the time and the date.
- Press the "STORE" key.
- The display will move to the next menu if the correct password has been entered. The next menu is "Time and Date Setting". The display will return to the normal weigh mode if a wrong password has been entered.
Note: You will have unlimited time in order to complete the password entry after the first number of the password has been entered. Press the CLEAR key in order to correct an error in entering the password.
Note: Press the "NEXT FUNCTN" key in order to skip setting the time and the date. If you are only changing the hours, press the "STORE" key after you have entered the correct hour. Then press the "NEXT FUNCTN" key.
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| Illustration 9 | g00583354 |
The month and the date will be displayed on the top line. The hour and the minutes will be displayed on the bottom line. The time is displayed in a 24 hour format.
Changing the Time and the Date
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| Illustration 10 | g00583356 |
- Place the system in weigh mode. Press the "NEXT FUNCTN" key.
- Enter the password. Press the "STORE" key.
- The month and the day are shown on the top line of the display.
- The hours are shown on the bottom line. The hours will start to flash.
- Press the desired digits for the hour. You may also press the "SCROLL" key in order to scroll through the hours. The time is in 24 hour mode. Press the "STORE" key in order to set the hours.
- The minutes will start to flash.
- Press the desired digits for the minutes. You may also press the "SCROLL" key in order to scroll through the minutes. Press the "STORE" key in order to set the minutes.
- The abbreviation for the month will flash.
- Press the "SCROLL" key in order to scroll through the desired months. Press the "STORE" key.
- The date will flash.
- Press the desired digits. The "SCROLL" key can also be used in order to advance one day at a time. Press the "STORE" key.
- "YEAR" is displayed on the top line. The current year will flash on the lower line.
- Press the desired digits for the year . The year must be between 1995 and 2176. Press the "STORE" key.
Note: On machines that are equipped with software package 2.06 and earlier, the date will need to be advanced from 1999 to 2000. This should be done as soon as possible in the new year.
- The display will now change to the next menu. The next menu is the "WEIGHING RANGE".
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| Illustration 11 | g00583443 |
This menu allows you to customize the weigh range to the particular application. It may be beneficial to lower the default weigh range when you are loading a hopper. The default weigh range is from 50 percent to 80 percent of the height of the lift arm. This range is usually adequate for loading trucks.
- Place the system in the weigh mode. Press the "NEXT FUNCTN" key. Press this key until "PWORD" is shown on the top line of the display.
- Enter the password of the owner. Press the "STORE" key.
- Press the "NEXT FUNCTN" key. The message "SHOW WEIGH BEGIN-STORE" will scroll across the top line of the display. The current height of the lift arm is displayed on the bottom line as a percentage of the total height of the lift arm. The bottom line will flash if the lift arm is below the current setting.
- Position the lift arm at the desired height for the beginning of weighing. The lift arm must be above 15% (150).
- Press the "STORE" key. The message "SHOW WEIGH END-STORE" will scroll on the top line of the display. The percent of the maximum height of the lift arm will flash on the bottom line. This will occur while the lift arms are in the current range.
- Position the lift arms at the top of the desired end of the weigh range.
- Press the "STORE" key.
Note: An error message that describes the problem will be shown on the top line if the range that is selected is not valid. For example, the message "RANGE TOO SMALL" may be shown on the display. The procedure will start again at the beginning of the weigh range. No permanent changes will be made to the weigh range. These changes will not be made until both settings have been entered successfully. There are only three limitations. The total range must be at least 15% of the travel of the lift arm. The end must be at least 95%. The beginning must be at least 15%.
- The display now changes to the next menu. The next menu is "Machine ID".
Note: The weigh range should be set in the area that has the smoothest operation. There are negative effects of improperly setting the weigh range. See the following list for some negative effects.
- Setting the weigh range too low may cause excessive "reweigh" indications. Setting the weigh range too low may cause inaccuracy of the weights.
- Setting the weigh range too high may also cause excessive "reweigh" indications. This will happen if you stop lifting the bucket in the weigh range. Setting the end at the maximum lift height will always cause a "reweigh" indication.
- Having a very limited weigh range may result in inaccurate weights. This is due to the limited number of samples that are taken by the system (ECM).
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| Illustration 12 | g00583547 |
This option allows the input of an identification number from 0 through 99999. If the number is not zero, this number will be shown on all printouts. This number will also be used in order to identify data that is downloaded to the off-board personal computer.
Setting the Identification Number of the Machine
- Press the "NEXT FUNCTN" key. Press this key until "PWORD" is shown on the top line of the display.
- Enter the password of the owner. Press the "STORE" key.
- Press the "NEXT FUNCTN" key. Press this key until "MACHINE ID" is shown on the top line of the display.
- Enter the machine Identification number. The number must be between 0 and 99999.
- Press the "STORE" key.
- The display will now change to the next menu. The next menu will be "Tickets Menu".
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| Illustration 13 | g00583609 |
This menu selects the number of printouts that will be automatically printed. The maximum number of printouts that will be automatically printed is three. The printouts will be printed automatically when the "STORE" button is pressed. Printouts can still be printed even if the option for automatic printing is deactivated. Press the "PRINT" key after the "STORE" key has been pressed in order to print a ticket. You must press the "PRINT" key before any additional weights have been taken.
- Press the "NEXT FUNCTN" key. Press this key until "PWORD" is shown on the top line of the display.
- Enter the password of the owner. Press the "STORE" key.
- Press the "NEXT FUNCTN" key. Press this key until "printouts MENU" is shown on the top line of the display.
- Press the "SCROLL" key in order to cycle between the desired number of printouts that will be printed.
- Press the "STORE" key. The display will now change to the next menu. The next menu is "Auto Truck ID".
Enabling and Disabling the Identification of Trucks
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| Illustration 14 | g00983984 |
This menu enables the automatic activation of the Truck ID function when the "STORE" key is pressed. This menu also disables the automatic activation of the Truck ID function when the "STORE" key is pressed.
Changing the Identification of Trucks
- Press the "NEXT FUNCTN" key. Press this key until "PWORD" is shown on the top line of the display.
- Enter the password of the owner. Press the "STORE" key.
- Press the "NEXT FUNCTN" key. Press this key until "AUTO TRUCK ID MENU" is shown on the top line of the display.
- Press the "SCROLL" key in order to activate the truck identification function or deactivate the truck identification function.
- Press the "STORE" key.
- The display will now change to the next menu. The next menu is "Operator ID".
Enabling or Disabling "OPERATOR ID"
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| Illustration 15 | g00583659 |
The automatic activation of "OPERATOR ID" can be enabled or disabled with this menu. "OPERATOR ID" is activated automatically when this function is enabled. "OPERATOR ID" is the first mode of the "Operator Setup" function.
Changing the "OPERATOR ID" Enabling or Disabling Setting
- Press the "NEXT FUNCTN" key. Press this key until "PWORD" is shown on the top line of the display.
- Enter the password of the owner. Press the "STORE" key.
- Press the "NEXT FUNCTN" key. Press this key until "OPERATOR ID MENU" is shown on the top line of the display.
- Press the "SCROLL" key in order to cycle the "OP ID" ON or OFF.
- Press the "STORE" key.
- The display will now change to the next menu. The next menu is "AUTO MATERIAL ID MENU".
Enabling and Disabling "Material ID"
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| Illustration 16 | g00583666 |
- Press the "NEXT FUNCTN" key. Press this key until "PWORD" is shown on the top line of the display.
- Enter the password of the owner. Press the "STORE" key.
- Press the "NEXT FUNCTN" key. Press this key until "AUTO MATERIAL ID MENU" is shown on the top line of the display.
- Press the "SCROLL" key in order to cycle the "MATERIAL ID" ON or OFF.
- Press the "STORE" key.
- The display will now change to the next menu. The next menu is "PRINTER MENU".
This menu allows the selection of the brand of printer. The printer can be any type of ASCII printer with a serial interface. If a printer is selected from the list, characters for languages in addition to English may be used.
Re-Zero (Re-Zero On*/Re-Zero Off)
When the Re-Zero Reminder is activated, the PCS contains software that will periodically remind the operator to Re-Zero the bucket. This reminder advises the operator when it is appropriate to Re-Zero but does not require the operator to comply. If the notice comes at an inopportune time, the reminder can be snoozed for two minutes by pressing the clear key. After two minutes, the reminder will reappear. Every time the reminder appears, the reminder must be either snoozed (for two minutes) or the bucket must be Re-Zeroed. The default setting for this feature is "Re-Zero On".
When the machine starts up, the Re-Zero reminder will appear fairly frequently (every five minutes). As the machine warms up and stabilizes, the reminder will appear less frequently (as infrequently as every thirty minutes).
Re-Zeroing the machine regularly will improve accuracy by compensating for machine bias that is associated with pin lubrication, oil temperature, and material carry-back.
Velocity Check (0 - 10* - 65536)
PCS contains software that monitors the lift speed in the weigh range. When the lift speed changes by more than the threshold that has been set in this menu location, PCS software will flag a bad lift. The threshold is in terms of percent/second*10. For example, if the threshold value was set to 20, a lift speed change of 2%/second would be enough to kick out the lift. The default setting for this feature is "10".
Setting this threshold to a high number will make the PCS more tolerant of changes in the lift speed. Setting this threshold to a low number will make PCS less tolerant of changes in the lift speed. Changing the lift speed in the weigh range will adversely affect the payload system's ability to calculate an accurate payload.
The default number provides a good balance between attaining good accuracy and allowing the operator to achieve high productivity. The threshold should be bumped up in small increments if the operator is maintaining a constant lift speed and is still receiving an excessive number of reweighs associated with lift speed.
Note: Moving the threshold up too far can compromise accuracy by giving the operator the capability to perform accuracy-compromising tasks during the weigh range. The most common accuracy-compromising tasks that are performed during the weigh range include moving the lift handle out of detent or changing engine speed.
Start of Lift (None - 5% - 10%* - 15%)
Start of Lift sets the amount of payload data that is gathered prior to the bucket entering the weigh range. The value is set as a percent of full lift travel and is relative to the bottom of the weigh range. The default setting for this feature is "10%".
Example 1 - The lift range is set from 50% to 80%. The Start of Lift is set for 10%. The PCS would begin gathering data at the 40% point.
Example 2 - The lift range is set from 40% to 70%. The Start of Lift is set for 15%. The PCS would begin gathering data at the 25% point.
The PCS maintains the same restrictions in the start of the lift range that is maintains in the weigh range (constant lift speed, modest lift noise, etc.).
The default setting of 10% provides sufficient lead data so that the PCS can obtain an accurate payload reading. Increasing this number to 15% will provide slightly better accuracy but will require the operator to maintain a constant lift speed for a larger part of the lift range. Decreasing the default setting to 5% or None will reduce the lift range where the operator needs to maintain a smooth steady lift but will adversely affect accuracy.
Display Resolution (AUTO* - 1 - 2)
This menu item provides a convenient method for setting the precision level that is provided by the PCS. The default setting for this feature is " AUTO", which maintains the same precision rules that were used in previous versions of PCS.
Setting this menu item to a value of 1 will force the PCS to display one digit of precision (30.2 tons). Setting this menu item to a value of 2 will force the PCS to display two digits of precision (30.23 tons).
Skew Resolution (Low* - Middle - High - None)
The PCS contains software that monitors the lift pressure during the weigh range and flags an error if the pressure bounces around excessively. This could happen under the following conditions:
- If the operator is weighing while travelling over rough terrain.
- If the operator started the lift so aggressively that the machine started bouncing up and down.
This feature will help the operator develop a good lifting technique that maintains loading productivity while still allowing PCS to calculate an accurate payload. The default setting for this feature is "Low". Setting this menu value to Middle, High, or None will make the PCS increasingly tolerant of machine and operator induced noise that can affect payload accuracy.
It is possible for a conscientious operator to get excessive re-weigh notices from Skew because of machine issues. The lift profile of some machines is so erratic that even the best operator can't get past the Low Skew threshold under the best of conditions. Under these circumstances, it is recommended that the Skew Resolution be set to Middle and the PCS re-evaluated. If the PCS continues to flag excessive Re-weighs for Skew after the Skew Resolution has been set to Middle, it can be bumped up to High. However, it would be better to first check the machine for the following problems:
- The validity of the calibration.
- Pin or pin lubrication problems.
- Operator technique.
- Valve and pump problems.
Generally, the Skew should only be set to High or None if accuracy is not an issue.
Temperature Compensation (0* - 65536)
The PCS contains software that compensates the payload for changes in hydraulic oil temperature (such as the machine cooling down after sitting idle for ten minutes). The default setting for this technique is "0" or OFF. This software requires some tuning by the service personnel. But, if the decision is made to use this software, the value can be set to match the machine. Tuning this feature is described later in this document.
Note: This feature is limited to machines equipped with CMS or VIMS.
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| Illustration 17 | g00730980 |
- Press the "NEXT FUNCTN" key. Press this key until "PWORD" is shown on the top line of the display.
- Enter the password of the owner. Press the "STORE" key.
- Press the "NEXT FUNCTN" key. Press this key until "ENTER NEW PASSWORD" is shown on the top line of the display. The bottom line shows the current password.
- Enter the new password.
- Press the "STORE" key.
- The message "END OF SETUP MENU" is displayed.
- The display now returns to "WEIGHING" mode.
Record the new password in a safe location. The new password is necessary for future calibrations and future changes. A product analyst can assist you if your password is lost. The product analyst will need to know the exact date that is displayed on the PCS in order to help you.
Resetting the Factory Password
The default password is 12345. The default password can be changed to a new password. If this new password is lost or unavailable, a product analyst must be notified in order to obtain a new factory password.
Use the following steps to enter the new factory password:
- When the system is in the WEIGH Mode, press the "NEXT FUNCTION" key until "PWORD" appears on the display.
- Enter the current factory password.
- Press the "STORE" key.
- Press the "NEXT FUNCTN" key until "ENTER NEW PASSWORD" is shown on the top of the display.
- Enter the new password.
- Press the STORE key.
- The message "END OF SETUP MENU" will scroll on the display. The display will return to the WEIGH Mode in 3 seconds.
The new factory password is now changed to a password that is selected by the owner.
Start of Lift and Weigh Range Discussion
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| Illustration 18 | g00989102 |
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Sample Lift Ranges | |
Illustration 18 illustrates several key terms that are used throughout this document. Lift height is described in percentage of a full lift. A bucket at the top of the machine's lift height (with the cylinders fully extended) is said to have a lift height of 100%. A bucket on the ground (with the cylinders fully retracted) is said to have a lift height of 0%.
The default PCS weigh range starts at 50% and ends at 80%. The default Start of Lift value is 10% or 10% before the Start of Weigh. If the Start of Lift setting remains unchanged, the Start of Lift will move up and down with the Start of Weigh. Refer to the examples below:
Example 1 - The Start of Lift would move down to 30% if the Start of Weigh was moved from 50% to 40% and the Start of Lift remained at 10%.
Example 2 - The Start of Lift would move up to 35% if the Start of Weigh remained unchanged and the Start of Lift setting was changed to 15%.
The machine must be lifting at a constant speed in the weigh range to achieve high accuracy. The machine should be fairly close to lifting at a constant speed between the Start of Lift and the Start of Weigh.
Setting the Temperature Compensation
Note: Temperature compensation must be turned on before the machine is calibrated. A good starting number for medium wheel loaders is 12.
Any one of the following methods can be used to determine the optimum temperature compensation coefficient for the machine that is being analyzed.
- Monitor the machine from day to day.
- Tune the number UP when the machine reads too heavy when the machine is cold (early in the morning) or when the machine reads too light when the machine is hot (after loading trucks).
- Tune the number DOWN when the machine reads too light when the machine is cold (early in the morning) or when the machine reads too heavy when the machine is hot (after loading trucks).
The optimum number will be found if the coefficient is slowly adjusted over a period of a few weeks.
- Exercise the pins immediately after the machine starts up but don't warm up the hydraulic oil.
- Load several trucks and compare the PCS weight to the scale weight (in pounds). To set up CMS to report oil temperature (on the screen in Mode 2 - Gage 3), record the hydraulic oil temperature. Oil temperature can be monitored using a 4C-8195 Control Service Tool.
- Warm up the machine to normal operating temperature and load several more trucks. Record the oil temperature, scale weight, and PCS weight.
- Calculate the PCS error by subtracting the PCS weight from the scale weight.
- Calculate the average error by summing the errors and dividing by the number of truckloads.
- Calculate the average temperature by summing the oil temperature for each lift and dividing by the number of truckloads.
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| Illustration 19 | g00989385 |
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Calculate Average Temperature Formula | |