V400 SERVICE MANUAL Table of Contents - Vulcan On
Contents
1. Figure 5 D VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 38 CHAPTER 5 Typical Rear Hinge Mounting Tipping Body CTI D Le 890 lb ft 2 and bend lock tabs ZERK FITTING lubricate the pillow block via the zerk fitting Figure 5 E Typical Front amp Middle Mountings Tipping Body MONOBLOCK 400 500 Ib ft 4 Figure 5 F Typical Rear Mounting Fixed Body VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 5 39 eS A 1 000 1 400 Ib ft CD 650 890 Ib ft 2 O O 2 OO 400 500 Ib ft 4 Figure 5 G Typical Front amp Middle Mountings Fixed Body Tighten to compress 1 000 1 400 Ib ft 2 the spring 1 4 Bend the tabs back Figure 5 H VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 40 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC CHAPTER 5 Doc 44 10016 001 Rev B CHAPTER 6 41 CHAPTER 6 0 TROUBLESHOOTING In general troubleshooting is a systematic process of testing and eliminating potential problem sources until the one that is causing the problem is found The problem can then be fixed by repairing or replacing the faulty part With a little knowledge and by following a step by step procedure most of the problems that you may encounter will b2. 100 kg perform the Leakage and Resistance tests refer to Sections 6 2 1 and 6 2 3 If all of the load cells wanders more than 200 Ib 100 kg then the Vulcoder is faulty and needs to be checked refer to Section 6 2 4 Vulcoder Check Out Procedure 6 4 4 CONDITION Meter Reading Does Not Change When Truck is Being Loaded Possible Causes 1 Voltage to meter is below 11 Volts 2 Mud or ice build up under the load cells 3 Calibration Number on the meter is set too low 4 Faulty load cell 5 Broken wire or bad connection between the load cell and Vulcoder 6 Meter display is locked What to Do 1 Using a voltmeter check the power at the meter s green plug at the back of the meter Refer to Section 7 3 System Specifications If the voltage is below 11 Vdc the problem could be in the power source battery meter power cable and or fuses 2 Reset the computer by unplugging the green connection on the back of the meter for a few seconds 3 Refer to Section 7 1 Starting Calibration Numbers to verify that the Cal Number is reasonable 4 Check the black cables between the load cells and the Vulcoder If the cabling is damaged the Vulcoder needs to be repaired or replaced Contact your Vulcan dealer 5 Perform the Leakage Tare and Resistance Tests refer to Sections 6 2 1 through 6 2 3 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 55 6 4 5 CO
3. Look up Cal Numbers for Channel A and B in Section 7 1 Starting Calibration Numbers and write them in the space provided below Starting Channel A Cal Number Starting Channel B Cal Number 4 Lock meter on Channel A using the Cycle button 5 Press and hold the Cal button to display the Cal Number setting If the setting doesn t match the starting Channel A Cal Number in Step 3 correct the Cal Number with the Up Down Arrow buttons Note Holding down the Up Down Arrow buttons will accelerate the number change 6 Lock meter on Channel B using the Cycle button T Press and hold the Cal button to display the Cal Number setting If the setting doesn t match the starting Channel B Cal Number in Step 3 correct the Cal Number with the Up Down VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 26 CHAPTER 4 Arrow buttons Note Holding down the Up Down Arrow buttons will accelerate the number change Use the Cycle button to lock the display on Channel A B IMPORTANT Leave the meter on for a minimum of 3 minutes after changing the Cal Numbers so the new values will be recorded into permanent memory Starting the truck turning the ignition switch or pressing meter buttons during this time may cause the meter to reset and return to a previous setting 4 2 2 PROCEDURE FOR ENTERING TARE WEIGHTS NET PAYLOAD WEIGHT METHOD With the truck empty and on level ground lock the meter on C
4. VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 45 6 2 2 TARE TEST PROCEDURE Required Equipment Vulcan V400 Meter Isopropyl Alcohol Cotton Swabs O Rings Hair Dryer Channel Lock Pliers Checks each load cell for a high Preload Number caused by mechanical damage or moisture 1 Park the empty truck on level ground Use the Cycle button to lock the meter on Channel A or B where the load cells will be tested Press the Tare button Record the Tare Weight Current Tare Weight Disconnect all load cells from the Vulcoder of the channel to be tested Press the Tare button Use the Up Down Arrow buttons to change the display to read zero Press and hold the Cal button Write down the current Cal Number Current Cal Number Then change the Cal Number using the Up and Down Arrow buttons to display 2050 Clean and re connect each load cell to the Vulcoder one at a time The meter will display the load cell Preload Number The Preload Number should not exceed 17 000 Ib to 12 000 Ib VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 46 CHAPTER 6 If the Preload Number exceeds 17 000 Ib to 12 000 Ib proceed with steps 7a 7e a Clean the load cell connector and cable connector with cotton swabs and isopropyl alcohol b Dry thoroughly with a hair dryer DO NOT OVERHEAT c Check the electrical isolation by performing the Leakage
5. 4 2 Net Payload Weight or Section 4 3 Gross Vehicle Weight Channel A New Cal Number Channel B New Cal Number Example Channel A New Cal Number 1935 Channel B New Cal Number 1935 4 load cell system Channel B New Cal Number 3580 6 load cell system VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 5 33 CHAPTER 5 0 MAINTENANCE In order to keep any system functioning properly it is important that the system be properly maintained This includes daily vehicle inspections and preventive maintenance 5 1 DRIVER S DAILY VEHICLE INSPECTION 1 Check load cells mounting brackets and fasteners Make sure they are secure 2 If torque stripes have been applied make sure they are properly aligned To apply a torque stripe Use a durable brightly colored paint Paint a stripe crossing the head of the fastener continuing down the fastened structure as shown Figure 5 A Painting a Torque Stripe VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 34 CHAPTER 5 3 Check and remove any build up of mud ice or other debris that may obstruct the load cell load path Refer to the drawing below and Section A in Figures 5 C through 5 H NO CONTACT LOAD PATH LOAD PATH LOAD PATH THE MOUNTING CAP SCREW HEADS LOAD PATH LOAD PATH Figure 5 B Load Path Diagram 4 Check the meter mounting and wiring make sure they
6. EmA or 24 242 neti set et ede ester E 50 s a ea ae es ae san ee 51 CONTENTS VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CONTENTS 3 6 4 System Malfunctions 51 6 4 1 No Indicator Display or Function Lights 91 6 4 2 Unable to Enter Tare or Calibration Numbers 92 6 4 3 Meter Reading Drifts or Wanders with Time 53 6 4 4 Meter Reading Does Not Change When Truck is Being Loaded 2 22 x RR RR REEL 54 6 4 5 Meter Restarts In Middle Of Operation And Will Display Normal Power Up Operating Sequence 55 6 5 Troubleshooting Worksheet 56 6 6 Troubleshooting Assistance and Replacement Parts 58 FA Appendix gt ud esd da eh cS ie OG RR Wom X xx ER REEL 59 7 1 Starting Calibration Numbers 60 7 2 Fine Tuning Your Scale System 61 7 3 System Specifications s eos eroepibetessueru uo ed V a 63 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CONTENTS VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 1 SG CHAPTER 1 0 VULCAN ON BOARD SCALE SYSTEM Vulcan On Board Scales are installed on all types of vehicles including front loaders rear loaders side loaders roll offs transfer trailers logging trucks flatbed trailers chip trailers a
7. a very high resistance to the load cell body An electrical path between the wires and the body would indicate moisture in the cell or shorting to the body This would result in erratic fluctuating or even out of range weight displays If the load cell fails electrical isolation is greater than 2 0 nS or is less that 500 Meg Ohms check the inside of the load cell connector with a dry cotton swab to make sure it is clean and dry If not clean with isopropyl alcohol dry with a hair dryer and check the electrical isolation again VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer Caution Do not touch the probes with your hands when making measurements This could cause an error in the meter reading A person s body can have 10 times the allowable conductivity of a load OR MULTI METER Gs A MULTI METER 2000 F3 2000 fal i Q WHITE BLACK LQ goo goo Jj GREEN RED LE SE CHECK OUT BOX z A I ot ie O SS p LLL mama LOAD CELL LOAD CELL Figure 6 B Leakage Test Leakage Test Specifications Measured between any pin and an unpainted clean surface of the load cell or connector body Electrical Isolation should not be greater than 2 0 nS or less than 500 Meg Ohms
8. are secure 5 Check the green plug attached to the back of the meter Make sure it is secure 6 Check the system Make sure the meter powers up after it has been turned on digits are legible and the system functions normally d Check all wiring for condition no cracks or splits security chaffing and protection from possible damage 8 Fixed body trucks Make sure springs are intact and bolt locks are in place 9 Tipper type trucks Check the bearing pads Make sure they are not worn out and properly aligned and greased Make sure bolt locks are in place hinge pins are not bent and body guides are intact VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 5 35 5 2 PREVENTIVE MAINTENANCE ANDVULCAN TORQUE SPECIFICATIONS The following simple but important preventive maintenance steps should be performed periodically after 500 miles monthly afterwards or more frequently if needed 1 Look for mud ice buildup or other debris between the load cell and bracket Refer to location A shown on Figures 5 C through 5 H 2 Check load cell connectors refer to location B shown on Figures 5 C through 5 F make sure they are finger tight plus an additional 1 8 of a turn with channel lock pliers The additional tightening is necessary to prevent scale errors which can occur from moisture entering into the load cell connector Do not grease or lubricate inside the Vulcan load cell co
9. needed to fine tune your scale system please follow the instructions shown in Section 7 2 Fine Tuning Your Scale System 1 Fully load the truck close to the legal limit 2 Lock the meter on Channel A B 3 Weigh the loaded truck using a certified platform scale Record the weight shown on the certified scale and the weight as shown on the V400 meter Channel A B a Weight Shown on Certified Scale truck fully loaded Example 56 240 Ib Certified Scale truck fully loaded b Weight Shown on V400 Meter truck fully loaded Channel A B Example 22 500 Ib V400 Meter truck fully loaded 4 Dump the payload 5 Weigh the empty truck on the same certified platform scale Record the weight shown on certified scale and the weight as shown on the V400 meter Channel A B a Weight Shown on Certified Scale truck empty VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 4 31 Example 35 000 Ib Certified Scale truck empty b Weight Shown on V400 Meter truck empty Channel A B Example 00 Ib V400 Meter truck empty 6 Calculate the Net Weight for both the Certified Scale readings P and the V400 meter readings V Subtract the truck empty weight from the truck fully loaded weight P Weight shown on Certified Scale truck fully loaded Weight shown on Certified Scale truck empty Example P 56 240 Ib 35 000 Ib 21 240 Ib V Weight sho
10. pin military type 11 0 to 16 0 Vdc 4 9 to 5 1 Vdc 1 5 to 3 mV V Automatically backlit liquid crystal display Variable cycle speed 1 9 seconds 10 100 Ib increments in Ib mode 10 50 kg in kg mode 99 900 to 124 500 Ib or kg 11 0 to 16 0 Vdc Across Red and Black Positive and Negative 11 0 to 14 0 Vdc Across Green and White Channel A 11 0 to 14 0 Vde Across Green and White Channel B 160 mA to 400 mA Internal reverse polarity and external 3 amp quick blow fuses Screw type quick release terminal block on rear panel 20 to 160 degrees F 17 oz including bracket Power cables fuses mounting bracket and thumb screws provided RS 232 output available contact factory for specifications VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 64 NOTES VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC CHAPTER 7 Doc 44 10016 001 Rev B
11. 58 10188 002 58 10188 004 58 10188 005 26 SHEAR BEAM L11 3075 5688 8271 HEAVY DUTY 58 10325 002 22 SHEAR BEAM LOG LO7 2100 3885 5649 LSR 58 10460 002 59 20500 001 CENTER HANGER L12 L13 L14 1950 3607 5245 58 10408 002 58 10408 001 58 10408 003 FIFTH WHEEL L04 L05 L16 2050 N A N A 58 10386 001 58 10386 003 58 10386 005 NOTES 1 Final Cal Number should be within 200 counts of Starting Cal Number If not troubleshoot the system for possible mechanical or electrical problem 2 Vulcoder Stock No VO9 designed for 7 Pin Connectors use Cal Number 5514 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 7 61 7 2 FINE TUNING YOUR SCALE SYSTEM For refuse applications only 1 Using the Cycle button lock the meter on Channel A B and be sure that TARE is not flashing 2 Fine tuning Complete a row of information each time using the same certified scale Do this six times filling in rows 1 through 6 Channel A Cal Number 2050 Channel B Cal Number 2050 for a 4 cell system or 3792 for a 6 cell system Truck Fully Loaded Truck Empty 3 When you have entered six certified scale weights call Vulcan Customer Service at 1 800 237 0022 to determine your fine tuned Cal numbers Enter the new Cal numbers in the meter Channel A New Cal Number Channel B New Cal Number 4 Confirmation Complete a row of information for six more certified scale weight
12. A and Channel B must be entered The Tare Weight is the weight of the empty truck with fuel equipment personnel and no payload For example if the Tare Weight is 30 000 Ib the meter would display this weight before any pick ups have been made As the pick ups are made and the payload increases the weight displayed on the meter will also increase The weight displayed at all times is the Gross Vehicle Weight 3 3 NET PAYLOAD WEIGHT VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 3 19 Net Payload Weight Weight of the truck s payload only By using the Net Payload Weight method pick ups are measured cumulatively Net Payload Weight can be measured when the truck s Tare Weight is set to zero If the Tare Weight for Channel A and Channel B are set to zero the weight displayed at all times during the route is the Net Payload Weight 3 4 NET PICK UP WEIGHT The Net Pick up Weight method can be used to determine the weight of individual pick ups The two methods used to determine Net Pick up Weight are the Continuous Tracking Method and the Isolated Pick up Method 3 4 1 CONTINUOUS TRACKING METHOD This method is used for weighing all customer pick ups on a route It is the most accurate quickest method and requires only simple subtraction at the end of the route Continuous Tracking Procedure 1 Lock meter on Channel A B 2 Stop the truck close to the first container on level ground w
13. C 52 CHAPTER 6 problem is most likely in the power source battery meter power cable or fuses If the new meter works but the old one doesn t the old meter is faulty If you do not have a spare meter disconnect then reconnect the green power plug on the back of the meter If the meter doesn t work then check the power source battery meter power cable or fuses If the power sources check out then the meter is faulty 6 4 2 CONDITION Unable To Enter Tare or Calibration Numbers Possible Causes 1 Meter may be in the Driver Lockout mode which does not allow the Tare Weight or the Cal Numbers to be changed without an access code 2 Faulty meter What to Do 1 Unplug the green connector at the back of the meter for a few seconds re plug 1t in and try to enter the Tare or Cal Numbers again 2 For meter revision P8 0 and higher refer to Section 4 1 Changing Cal Numbers and Tare Weights When the Driver Lockout Feature is Enabled 3 Faulty meter Call your Vulcan dealer for meter replacement The meter contains no user serviceable parts VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 53 6 4 3 CONDITION Meter Reading Drifts or Wanders With Time Possible Causes 1 Voltage to meter or Vulcoder is less than 11 Volts 2 Voltage out of the Vulcoder is less than the Voltage Output Required as stated in Section 7 3 System Specifications 3 Moist
14. CONTENTS 1 V400 SERVICE MANUAL Table of Contents 1 0 Vulcan On Board Scale System 5 1 1 OARS GI Siete O ciety sis tg sts oh ths ha a ah ROP POB 6 1 25 UICOOCIS s eepHbrpsrbrFPHPPRDPRERFRPHPRPREFRDHPFRDPREFRDHPPRDRERLDU 7 1 9 Metel Siac Rad mi ERE USA SE Edid It tds d ba qt 7 1 4 Electronics Installation 9 20 Meter Operation 11 2 1 Turning the Meter OU cues esos Des D we ee XE ES EN 11 2 2 Adjusting the Cycle Time 11 2 3 Locking the Meter on a Particular Channel 11 24 Displaying Tare Weight 4 442 13 2 5 Displaying Calibration Numbers 13 2 6 Changing the Display Graduation 13 2 Switching Between lb and kg 13 2 5 Driver LOCKOUL 232522 dense boha feeb pane deed 6 14 29 Polb sc eere eri RARE eee AR ets ed MEANS 16 3 0 Weight Measuring Methods 17 Oo AXI Wege secs ner nee ee Cee LIRE RM NUI 18 3 2 Gross Vehicle Weight 2 259 0 A eere 18 3 3 Net Payload Weight x i A 19 3 4 Net Pick up Weight O pi b o osi bos 19 3 4 1 Continuous Tracking Method 19 3 4 2 Isolated Pick up Method 21 4 0 Calibration and System Set Up 23 VULCAN ON BOARD SCALES 1 800 237 0022
15. Doc 44 10016 001 Rev B STRESS TEK INC 4 1 Changing Calibration Numbers and Tare Weights 24 When the Driver Lockout Feature is Enabled 4 2 Calibrating for Net Payload Weight 25 4 2 1 Procedure for Entering Starting Calibration Numbers 25 4 2 2 Procedure for Entering Tare Weights 26 4 3 Calibrating for Gross Vehicle Weight 27 4 3 1 Procedure for Entering Starting Calibration Numbers 27 4 3 2 Procedure for Entering Tare Weights 28 4 4 Final Calibration Procedure for 30 Net Payload Weight and Gross Vehicle Weight Methods 5 0 Maintenance ol rassurer ewe thea ees 33 5 1 Driver s Daily Vehicle Inspection 33 5 2 Preventive Maintenance and Vulcan Torque Specifications 35 6 0 Troubleshooting 41 6 1 Vulcan Check Out BOX a x ey cae ads c RC Re aa 42 6 2 Load Gell Evaluation Tests 3445 46 sus us su sas d sas 43 6 2 1 Leakage Test Procedure 43 6 2 2 Tare Test Procedure ne oL A 45 6 2 3 Resistance Test Procedure 47 6 2 4 Vulcoder Check Out Procedure 48 6 3 V400 Meter Error Codes 48 SES ay aj Meer en ee en tet d aia eam e e er 49 OL 2 ENT Asus hos d bee we oe Se eae wed Nea eS 49 BO OBS etttiite iets sat ieee eet biis 50 od
16. LAYING TARE WEIGHT Lock the meter on Channel A or B The Tare Weight is the displayed reading when the vehicle is empty For setting the Tare Weight refer to Chapter 4 0 Calibration and System Set up DISPLAYING CALIBRATION NUMBERS Lock the meter on Channel A or B Press and hold the Cal button to display the Calibration Number For setting the Calibration Numbers refer to Chapter 4 0 Calibration and System Set up CHANGING THE DISPLAY GRADUATION Cycle to Channel A B and lock on it Push the Tare button This will cause the word TARE to flash in the lower right corner of the display The meter display will read 0 and will display positive or negative weight change in 10 lb or 10 kg mode increments To return to normal operating mode push the Tare button once To re zero the display while in the 10 Ib or 10 kg mode push the Tare button twice SWITCHING BETWEEN LB AND KG Turn the meter off press both the Up and Down buttons while turning the meter back on Continue to hold the Up and Down buttons until the start up routine is complete 5 seconds VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 14 CHAPTER 2 2 8 DRIVER LOCKOUT Available on Meter Versions P8 0 and Higher The Driver Lockout option is available on V400 meter software versions P8 0 and higher This option prevents drivers or other unauthorized personnel from changing the calibration settings on their s
17. NDITION Meter Restarts In Middle Of Operation And Will Display Normal Power Up Operating Sequence Possible Causes 1 An interruption on the power lines What to Do 1 The power connections and fuses must be inspected and cleaned 2 The power cord must connect directly to the batteries VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 56 CHAPTER 6 6 5 TROUBLESHOOTING WORKSHEET Briefly describe your problem Do you have Vulcan electronics If not whose Do you have all Vulcan load cells If not whose Channel A load cells If not whose Channel B load cells HISTORY Were the scales put on a new vehicle or were they retrofitted How long have you had this system Has the system ever worked How long has the current driver been using the vehicle Has there been any mechanical work or maintenance done to the vehicle changed bridge beam bunk etc Has there been any electrical work or maintenance done to the vehicle battery work generator alternator problems added accessories jump start Has there been any recent maintenance of the scale system parts exchanged etc Has anything else happened to the rig such as an accident SYMPTOMS Does the problem occur on Channel A or B or both Does the meter drift up and or down fast or slow or both Is the problem intermittent constant or both Does problem occur on flat road or off road or both Does it occur in wet o
18. Test Refer to Section 6 2 1 d If a Vulcan Check Out Box is available perform the Vulcoder Check Out Test Refer to Section 6 2 4 e Check the Preload Number again to see if it is within the 17 000 Ib to 12 000 Ib range If the load cell is still out of range it may be faulty Perform the Resistance Test Refer to Section 6 2 3 f Replace the O rings before re connecting 8 Measure the Preload Number of the remaining load cells one at a time 9 Reset the original Cal Number and Tare Weight If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 47 6 2 3 RESISTANCE TEST PROCEDURE Required Equipment Multi meter Optional Equipment Vulcan Check Out Box Please refer to drawing below in setting up the Resistance Test The resistance in the pins should correspond to the Vulcan specifications listed below This test can be conducted with a multi meter or a Vulcan Check Out Box Refer to acceptable resistance ranges as shown below OR MULTI METER AN MULTI METER E ES A goo WHITE BLACK GREEN RED o o ZE CHECK OUT BOX E C LOAD CELL 2 Bo M8 E LOAD CELL Figure 6 C Resistance Test Pins Terminal Acceptable Color Code Resistan
19. a system to maximum accuracy in reference to a specific certified platform scale It is important to calibrate for high accuracy in order to achieve the maximum possible payload It is also important that conditions remain as constant as possible throughout the calibration process Inaccuracies may result from differences in fuel load ice build up etc It may take 2 or 3 attempts at calibration to achieve the optimum setting Calibration should be done anytime a system is installed if there are continuous questionable readings or if meter readings repeatably do not closely match the certified platform scale weights The Vulcan Scale System can be calibrated for either Net Payload Weight or Gross Vehicle Weight The Net Payload Weight displays only the weight of the payload and the Gross Vehicle Weight displays the weight of both the truck and its payload VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 24 4 1 CHAPTER 4 CHANGING CALIBRATION NUMBERS AND TARE WEIGHTS WHEN THE DRIVER LOCKOUT FEATURE IS ENABLED The meter s access code must be entered in order to make changes to the Calibration Numbers and Tare Weights if the Driver Lockout feature has been enabled The procedure for changing Calibration Numbers and Tare Weights when the Driver Lockout feature is enabled is shown below 4 2 Turn the meter off Press the Up Arrow button while turning the meter on with the Power button Cont
20. ad weight change Figure 1 B Vulcan Shear Beam Load Cell U S Patent 4 666 003 Canadian Patent 1 245 677 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 1 LLL A 1 2 VULCODERS The primary functions of the Vulcoder are to supply the load cells with power and to relay the load cells output to the meter The Vulcoder receives a 12 Vdc input from the meter and supplies the load cells with 5 Vdc 1 Vdc When weight is applied the voltage output of the load cells change The Vulcoder then reads the change in voltage from the load cells and converts it from an analog to a digital signal This signal is then relayed to the meter and displayed as weight 12Vdc 5Vdc 1Vdc 12 Vdo L WEIGHT Lb Kg ANALOG DIGITAL OUTPUT CONVERTER 5 mV V V400 METER DIGITAL VULCODER ANALOG LOAD CELLS SIGNAL SIGNAL Figure 1 C Vulcan Electronics Diagram 1 3 METER The V400 meter s primary functions are to supply the Vulcoder with 12 Vdc and to read the digital signal transmitted from the Vulcoder The meter reads the digital signal makes calculations and displays a weight in pounds or kilograms The V400 meter is shown on the following page together with a description of the meter button functions VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 8 CHAPTER 1 TARE CAL V400 Series Ki Figure 1 D V400 Me
21. as been stored in permanent memory The meter then returns to normal operating mode in the lockout state 5 Verify the Driver Lockout access number by pressing the Cycle button Note Ifthe correct access number is not verified the meter will return to the normal locked state 6 Record the access number and store it in a safe place Access Number Quick Reference Steps Access Driver Lockout Mode Put the meter in lockout programming mode refer to Steps 1 and 2 above Deactivate Driver Lockout To deactivate the Driver Lockout feature enter 0000 as an access number in Step 3 above Verify Access Number To verify the Driver Lockout access number refer to Step 5 above VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 16 CHAPTER 2 2 9 SET POINT Available on Meter Versions P8 0 and Higher The Set Point Option is available on V400 meter software versions P8 0 and higher This option will alert the driver when a pre determined weight has been reached The Set Point Option is available on Channel A B only and has a range from 0 to 124 500 Ib 0 to 56 550 kg It can be entered either as gross vehicle or total net weight When this weight is exceeded all of the meter channels will continuously flash until the weight on Channel A B goes below the Set Point Value Entering a Set Point Value 1 Turn the meter off 2 Press and hold the Tare button while turning on the meter with
22. attery for best operation If not connecting directly to the battery be sure to use a location that has the proper 12 Vdc available at all times refer to Section 7 4 System Specifications VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 10 CHAPTER 1 Note Some trucks are configured with variable voltage supplies never apply more than 16 Vdc to the Vulcan system Apply grease to the positive connector at the battery post to inhibit corrosion 8 Review steps to 7 before connecting terminal block to back of meter STRIPPING WIRES FOR METER 1 4 TWIST TIGHTLY DO NOT SOLDER Be careful that stray wires DO NOT contact adjacent terminals Figure 1 E Stripping Wires for Meter 15 PIN SERIAL PORT ON THE V432 METER h V400 METER BACK VIEW ORANGE CABLE Figure 1 F Wire Connections to Meter VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 2 11 CHAPTER 2 0 METER OPERATION 2 1 2 2 2 3 TURNING THE METER ON This can be done by turning the truck s battery cut off switch on and by pressing the Power button on the meter ADJUSTING THE CYCLE TIME The Cycle Time is the amount of time each channel is displaved on the meter and can be adjusted from 1 to 9 seconds To adjust the Cycle Time press and hold the Cycle button until a single digit number is displaved While continuing to hold the Cycle button use th
23. been damaged 4 A load cell is faulty 5 A load cell has a large Preload Number What to Do 1 Check and verify that the Cal Number is reasonable Refer to Section 7 1 Starting Calibration Numbers 25 Perform Tare Test refer to Section 6 2 2 3 Check the load cells Check by disconnecting one load cell at a time When the faulty load cell has been disconnected the meter will read a number instead of the error code 4 Check mounting of the load cell per Section 5 2 Preventative Maintenance and Vulcan Torque Specifications Figures 5 C to 5 H 6 3 2 Err 2 Indicates that the reading to be displayed is beyond the limitations of the meter s display Possible Causes 1 Cal Number set too high 2 Tare Weight set too high What to Do l Check and reset Cal Numbers and Tare Weight 6 3 3 Err 3 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 50 CHAPTER 6 Indicates that the meter is not receiving a signal from the Vulcoder Possible Causes 1 There is usually an open circuit between the meter and Vulcoder This is the most common reason Pa Disconnected or broken green or white Vulcoder wires between the back of the meter and the Vulcoder 3 Faulty Vulcoder or meter 4 Faulty load cell 5 Moisture in the load cell connectors What to Do 1 Check the wires in the green plug at the back of the meter and ensure that they are firmly in place Unplug and plug th
24. bration Numbers and write them in the space provided below Starting Channel A Cal Number Starting Channel B Cal Number 4 Lock meter on Channel A using the Cycle button 5 Press and hold Cal button to display Cal Number setting If setting doesn t match Starting Channel A Cal Number in Step 3 correct the Cal Number with the Up Down Arrow buttons Note Holding down the Up or Down Arrow buttons will accelerate the number change 6 Lock the meter on Channel B using the Cycle button VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 28 CHAPTER 4 Press and hold Cal button to display Cal Number setting If setting doesn t match Starting Channel B Cal Number in Step 3 correct the Cal Number with the Up Down Arrow buttons Note Holding down the Up or Down Arrow buttons will accelerate the number change Use the Cycle button to lock the display on Channel A B IMPORTANT Leave the meter on for a minimum of 3 minutes after changing the Cal Numbers so the new values will be recorded into permanent memory Starting the truck or turning the ignition switch during this time will cause the meter to reset and go back to a previous setting 4 3 2 PROCEDURE FOR ENTERING TARE WEIGHTS GROSS VEHICLE WEIGHT METHOD Weigh the entire empty truck both front and rear axles using a certified platform scale This is the truck s Tare Weight Enter this number in the space provided Tare Weig
25. cale system The Calibration Number and Tare Weight can only be changed by successfully entering the correct four digit access number Once an access number has been stored in permanent memory the meter will be in the lockout state every time it is turned on The Driver Lockout access number is any four digit number between 0001 and 9999 When an access number is stored in permanent memory it replaces any previous access number If access number 0000 is stored in permanent memory the Lockout feature is deactivated The meter should arrive from your Vulcan dealer deactivated However if the meter is in the lockout state when received enter 0000 to deactivate the Driver Lockout feature Procedure for Entering a Driver Lockout Access Number is shown on the following page VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 2 15 ENTERING A DRIVER LOCKOUT ACCESS NUMBER 1 Turn the meter off 2 Press and hold the Up Arrow button while turning the meter on with the Power button Continue holding the Up Arrow button until four zeros appear on the display 3 Use the Up and Down Arrow buttons to input an access number between 0001 and 9999 To deactivate the Driver Lockout feature enter 0000 as an access number 4 Press the Cal button to store the access number in permanent memory The display will flash three times indicating that the access number h
26. ce Range A to D Red to Black 349 to 400 Ohms B to C Green to White 349 to 352 Ohms Note For Center Hanger Load Cells Red to Black 349 to 450 Ohms Pin B Green to Pin A Red should be the same number as Pin B Green to Pin D Black within 1 Ohm Pin C White to Pin A Red should be the same number as Pin C White to Pin D Black within 1 Ohm If the load cell cannot be brought to Vulcan specifications contact your Vulcan dealer VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 48 CHAPTER 6 6 2 4 VULCODER CHECK OUT PROCEDURE Required Equipment Vulcan V400 Meter Vulcan Check Out Box Using the Cycle button lock the meter on the Channel that the Vulcoder will be tested on either Channel A or B Set the Calibration Number to 2050 on the channel being tested Set the Tare Number for that channel to zero using the following procedure Disconnect all load cells from Vulcoder on the channel being tested Depress the Tare button and use the Up and Down Arrow buttons to make the display read zero The display must read zero while the Tare button is depressed Release the Tare button With all load cells disconnected on the channel being tested plug a Vulcoder lead into the Check Out Box load switch OFF The meter display should read zero 200 Ib If it does not the Tare Number is not zeroed or the cabling is damaged Move the load switch to ON indicted by the red dot The V400 m
27. ck up Procedure 1 Lock meter on Channel A B 2 Stop the truck close to the container on level ground with forks lowered 3 Press the Tare button to put the meter into the 10 Ib mode The TARE indicator will flash and the meter display will go to zero 20 Ib kg Pick up the load gras Dump it into the vehicle Set the container down o gt Back the forks out of container e Stop the truck with forks in the down position on level ground Note The truck should not be in a twist or turn f Ifthe body lift cylinder pressure is not relieved automatically bleed the pressure manually 5 Write down the meter reading In order to avoid weight measurement errors it is important that the truck not touch the container or any other object while a meter reading is being taken 6 Press the Tare button to view accumulated weight mode and proceed to the next customer Repeat the above procedure for the next customer to be audited VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 22 CHAPTER 3 Example Customer Weight Displayed Individual Total Payload On The V400 Meter Pick up Weight Weight Meter Reading Before Pick ups 00 0 0 Pick up 1 300 280 280 Pick up 2 1000 700 980 Pick up 3 1200 250 1230 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 4 23 CHAPTER 4 0 CALIBRATION AND SYSTEM SET UP Calibration is fine tuning
28. e Up Down Arrow buttons to adjust the time LOCKING THE METER ON A PARTICULAR CHANNEL To lock the meter on a particular channel press the Cycle button until the channel is displayed Example A B CYCLE Press the Cycle button again until the CYCLE indicator disappears from the meter display Example A B The meter 1s now locked on a specific channel Example Channel A B To lock the meter on a particular channel for power up Cycle the display to the desired channel and lock on it Turn the meter off using the Power button and turn the meter back on The meter will now repeatedly power up locked in that channel when power is disconnected Channel Designations for Figures 2 A and 2 B Channel A Represents the front load cells regardless of whether it is a four or a six cell configuration Channel B Represents the rear load cells Channel A B Represents the total weight from the front and rear load cells VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 12 CHAPTER 2 LOAD CELL LOAD CELL VULCODER LOAD CELL LOAD CELL CHANNEL A CHANNEL B VULCODER LOAD CELL LOAD CELL LOAD CELL VULCODER VULCODER LOAD CELL LOAD CELL LOAD CELL CHANNEL A CHANNEL B Figures 2 A and 2 B Vulcan 4 and 6 cell configurations VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 2 13 2 4 2 5 2 6 2 7 DISP
29. e connector back in the meter to check for proper connection 2 Check the voltage at the back of the meter and Vulcoder Make sure the voltages match the required voltages in Section 7 3 System Specifications d Check the orange cable for broken wires 4 Check the voltage at the load cell connector Refer to the required load cell voltages in Section 7 3 System Specifications Repair or replace the Vulcoder as necessary 5 Disconnect one load cell and then the other to see if this clears the error code If the error code is cleared the load cell may be faulty Conduct all three load cell tests Leakage Tare and Resistance refer to Sections 6 2 1 through 6 2 3 6 Replace the O rings clean the connector with isopropyl alcohol and dry with a hair dryer Reconnect the load cells 6 3 4 Err 4 Same as Err 2 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 51 6 3 5 Err P V400 METER VERSIONS P8 02 AND HIGHER SOFT WARE Err P Indicates that the meter has had a system reset and will display Err P for 10 seconds then operate properly Possible Causes 1 The software fault detector has detected an interruption in software processing This is usually caused by a voltage spike or very short interruption in power What to do 1 On some trucks Err P will occur occasionally If this type of reset occurs freguently or constantly check and clean the power connectio
30. e easy to diagnose and cure In this section you will find guidelines on how to troubleshoot the system some characteristics of a properly functioning system and where to look when certain problems occur Occasionally someone has a problem that is not described here Don t panic By approaching the problem systematically you will be able to eliminate potential sources of trouble until you find the one that is causing the problem The following section covers an explanation of Load Cell Evaluation Test Procedures and Vulcan Error Codes If a problem occurs and no Error Codes appear use the V400 Meter to isolate the problem to either Channel A or B VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 42 CHAPTER 6 6 1 Vulcan Check Out Box The Vulcan Check Out Box works as an extension to bring connector pins to the side of truck where readings can be conveniently made and it can also simulate an applied load to the Vulcoder The Check Out Box is required equipment for the Vulcoder Check Out Procedure Section 6 2 4 and is an optional equipment item for the Leakage and Resistance Tests Section 6 2 1 and 6 2 3 Before using the Check Out Box make sure the meter fuses are good Use a multi meter to ensure there is a minimum of 11 Vdc at the back of the meter make sure the green plug is plugged in and the meter is turned on If there are any error messages displayed refer to Section 6 3 V400 Met
31. er Error Codes o 8 o y CONNECTOR o TO VULCODER OFF ON LOAD SWITCH S o4 RED DOT WHITE BLACK CHECKOUT CREEN RED BOX CONNECTOR TO LOAD CELL CABLE 4FEET Figure 6 A Vulcan Check Out Box To order a Check Out Box P N 56 10425 001 contact your Vulcan dealer 6 2 LOAD CELL EVALUATION TESTS VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 43 The tests listed below will help identify and locate any problem you may encounter with your Vulcan Scale System Leakage Test Tare Test Resistance Test Vulcoder Check Out Test 6 2 1 LEAKAGE TEST PROCEDURE Required Equipment Multi meter Isopropyl Alcohol Cotton Swabs Hair Dryer Optional Equipment Vulcan Check Out Box The Leakage Test Procedure detects the presence of moisture that could cause erratic meter readings The way to measure leakage is to use a digital multi meter that has a conductivity scale Electrical Isolation is measured between any pin and an unpainted clean surface on the load cell or the connector body Electrical isolation should not exceed 2 0 nS nano siemans or be less than 500 Meg Ohms Refer to Figure 6 B for the Leakage Test equipment set up If a Vulcan Check Out Box is used it is important that the Vulcoder leads from the load cells of the channel being tested are disconnected For proper operation the power and signal leads from the load cell must have
32. eter should display 33 200 Ib 200 Ib Check all leads if any Vulcoder lead does not perform as stated above the black Vulcoder cable is damaged and must be inspected and repaired If all Vulcoder leads do not perform as stated above all have been damaged or the Vulcoder needs to be replaced Contact your Vulcan dealer for repair or replacement of damaged Vulcoder lead 6 3 V400 METER ERROR CODES The V400 Meter is equipped with a self diagnostic program Should a malfunction occur the meter will display an error code This error code can be used to isolate and identify a problem with the Vulcan Scale System If an error code is displayed on the screen while the meter is locked on Channel A B use the Cycle button to isolate the problem to either Channel A or Channel B VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 49 Listed below are the error code definitions possible causes and procedures to correct the system malfunction 6 3 1 Err 1 Indicates that the Vulcoder is processing an over ranged signal An over ranged signal means that the load cell output is greater than the maximum that the Vulcoder will accept Err 1 is displayed briefly when the meter is first turned on and clears after the meter and Vulcoder get in synch Possible Causes 1 The load cells are being over loaded 2 There is moisture in a load cell connector 3 One of the Vulcoder to load cell cables has
33. hannel A using the Cycle button The displayed weight is the Tare Weight Note The truck should not be in a twist or turn Press and hold the Tare button Use the Up Down Arrow buttons until the meter displays Zero Lock the meter on Channel B using the Cycle button The displayed weight is the Tare Weight Press and hold the Tare button Use the Up Down Arrow buttons until the meter displays Zero Lock the meter on Channel A B for normal operation IMPORTANT Leave the meter on for a minimum of 3 minutes after changing the Tare Weight so the new values will be recorded into permanent memory Starting the truck turning VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 4 27 the ignition switch or pressing meter buttons during this time may cause the meter to reset and return to a previous setting 4 3 CALIBRATING FOR GROSS VEHICLE WEIGHT If the Cal or Tare Numbers cannot be entered according to the procedures listed below the Driver Lockout feature may be enabled Refer to Section 4 1 Changing Calibration Numbers and Tare Weights When The Driver Lockout Feature is Enabled for further information 4 3 1 PROCEDURE FOR ENTERING STARTING CALIBRATION NUMBERS GROSS VEHICLE WEIGHT METHOD 1 Stop the empty truck on level ground 2 Turn on the meter Wait 5 seconds for system initialization 3 Look up Cal Numbers for Channel A and B in Section 7 1 Starting Cali
34. ht of Entire Truck Weigh the rear axle group of the empty truck This is the Rear Axle Tare Weight Enter this number in the space provided below Tare Weight of Rear Axle Group Stop the empty truck on level ground Enter the Tare Weight of the Rear Axle Group as Channel B a Press the Cycle button to lock on Channel B b Press and hold the Tare button VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 4 29 c Use the Up Down Arrow buttons until the desired value from Step 2 is shown 5 Subtract the Tare Weight of the Rear Axle Group form the Tare Weight of the Entire Truck and enter this number on Channel A a Press Cycle to lock on Channel A b Press and hold the Tare button c Use the Up Down Arrow buttons until the desired value is shown 6 IMPORTANT Leave the meter on for a minimum of 3 minutes after changing the Tare Weight so the new values will be recorded into permanent memory Starting the truck turning the ignition switch or pressing meter buttons during this time will cause the meter to reset and return to a previous setting VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 30 CHAPTER 4 4 4 FINAL CALIBRATION PROCEDURE FOR NET PAYLOAD WEIGHT AND GROSS VEHICLE WEIGHT METHODS Listed below is the final calibration procedure for both the Net Payload Weight and Gross Vehicle Weight Methods If additional assistance is
35. inue holding the Up Arrow button until four zeros appear on the display Use the Up and Down Arrow buttons to input the access number Press the Cycle button so the meter can verify the access number If the correct access number is entered the meter will enter an operating mode where the Calibration Numbers and Tare Weights can be changed If an incorrect access number is entered the Driver Lockout feature remains active To deactivate the Driver Lockout feature enter 0000 as the access number After the desired Calibration Numbers and Tare Weight changes have been made leave the meter on for 30 seconds to store the new numbers into permanent memory Turn the meter off with the Power button and back on again The meter will return to the Driver Lockout state again with the new Cal and Tare numbers stored in permanent memory CALIBRATING FOR NET PAYLOAD WEIGHT VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 4 25 If the Calibration or Tare Numbers cannot be entered according to the procedures listed below the Driver Lockout feature may be enabled Refer to Section 4 1 Changing Calibration Numbers and Tare Weights When The Driver Lockout Feature is Enabled for further information 4 2 1 PROCEDURE FOR ENTERING STARTING CALIBRATION NUMBERS Net Payload Weight Method 1 Stop the empty truck on level ground 2 Turn on the meter Wait for system initialization 3
36. ith forks lowered Note The truck should not be in a twist or turn 3 Press the Tare button to put the meter in the 10 Ib mode The TARE indicator will flash and the meter display goes to zero 20 Ib kg 4 Write down the meter reading In order to avoid weight measurement errors it is important that the truck not touch the container or any other object while a meter reading is being taken VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 20 CHAPTER 3 a Pick up the load b Dumpit into the vehicle c Set the container down d Back the forks out of container e Stop the truck with forks in the down position on level ground Note The truck should not be in a twist or turn f Ifthe body lift cylinder pressure is not relieved automatically bleed the pressure manually Write down the meter reading In order to avoid weight measurement errors it is important that the truck not touch the container or any other object while a meter reading is being taken Repeat steps 5 and 6 until the truck is fully loaded Subtract the previous reading from the current reading to determine the weight of each pick up VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 3 21 3 4 2 ISOLATED PICK UP METHOD This method is used for auditing selected customers on a route and requires two stops of the truck for every pick up site Isolated Pi
37. nd any commercial vehicle requiring scales Individual commercial account pick up weights and total truck payload weights can be measured using the Vulcan On Board Scale System Typically a scale system has either four or six load cells two Vulcoders and one meter per truck The number of load cells required depends on the truck s length and the load capacity Vulcan Scale System Load Cells Vulcoders Meter M V400 METER L LOAD CELL a V VULCODER NC uU Figure 1 A Vulcan Scale System Diagram VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 6 CHAPTER 1 1 1 LOAD CELLS Vulcan load cells are machined high strength steel beams with strain gages bonded inside The load cells have no moving parts A strain gage is an electrical resistance element When weight is applied to the load cell the strain gages stretch and compress causing a change in voltage signal This voltage signal is then used to determine weight Calibration Circuit All wiring is routed internally through long holes drilled from each end of the load cell Shear section provides maximum strength and high accuracy Environmentally H sealed connector i All internal cavities Strain gage are sealed with a bonded to chemical and weather shear web Weld down resistant elastomer measures bearing p
38. nnector or Vulcoder connector These components are highly sensitive to foreign substances and inaccurate readings will occur if these components are contaminated Your manufacturer s warranty does not cover the failure of Vulcan components due to contamination use of grease or other conductive substance in either the Vulcan load cell connectors or Vulcoder connectors Ifa connector is opened for any reason you must clean the load cell connector and cable connector with cotton swabs and isopropyl alcohol dry with a hair dryer DO NOT OVERHEAT and replace the O ring before reconnecting 3 Check the torque on load cell cap screws monthly New trucks should be checked once a week for 2 weeks Vulcan On Board Scales recommended torque values are shown on Figures 5 C through 5 H and on the following page As a method of monitoring changes in fastener torque Vulcan On Board Scales recommends applying torque stripes to all fasteners see Section 5 1 step 2 Torque Specifications 3 4 7 8 1 1 1 8 1 1 4 lb ft 400 500 400 590 650 890 1000 1400 1450 1780 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 36 6 grease 10 11 12 CHAPTER 5 Vulcan load cells are plated for increased rust protection Certain minimum maintenance will be necessary to claim warranty of load cells Annually apply a high quality paint to the load cells bearing pads and mounting brackets For envi
39. ns and fuses If this doesn t cure the problem then the power cord must be connected directly to the battery 6 4 SYSTEM MALFUNCTIONS 6 4 1 CONDITION No Indicator Display Or Function Lights Possible Causes Power switch turned off Power to the meter has been disconnected Bad meter cable connections to the battery Battery is low under 11 Volts A fuse is blown in the power or ground cable Meter s internal circuit breaker is blown Faulty power switch Faulty meter Reversed polarity BOC PREN ON ae NI What to Do 1 Check the power to the meter When the meter is turned on and off the power should not change more than 1 2 Volt Turn off the meter either by the key or truck battery switch for a few seconds and then turn on again If the meter still does not work proceed to step 2 2 Check the fuses for both negative and positive leads Use 3 amp quick blow fuses only 3 Check that the power supply wires are attached correctly at the 12 Volt power source and to the green connector at the back of the meter Check the battery connections for corrosion 4 If a spare meter is available the quickest and easiest next step is to exchange the meter Ifthe new meter works try the old meter again If the old meter now works the problem was likely the meter s internal circuit breaker If both the old meter and the new meter do not work the VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK IN
40. r dry weather or both VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 6 57 Does it occur at morning at night or both Does it occur when empty loaded or both INSPECTION Has the same platform scale been used to check scale accuracy Is the power cable connected directly to the battery Have you checked fuses in both power and ground wires Are you using Vulcan yellow fuse holders Are you using Vulcan orange cable or trailer light cable Is there mud or ice build up between the load cell pads and vehicle frame Is there any contact on top of the load cell mounting cap screw heads VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 58 CHAPTER 6 6 6 TROUBLESHOOTING ASSISTANCE AND REPLACEMENT PARTS If you need additional assistance parts or service give us a call at VULCAN CUSTOMER SERVICE 1 800 237 0022 HOURS 7 30 a m 5 00 p m PACIFIC TIME VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 7 59 CHAPTER 7 0 APPENDIX VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 60 CHAPTER 7 7 1 STARTING CALIBRATION NUMBERS LOAD CELL VULCODER V08 V13 V14 V15 NO 2L C 4L C 6LC 15 SHEAR BEAM LO1 LO2 2050 3792 5514 58 10411 002 58 10411 001 17 SHEAR BEAM L03 2050 3792 5514 SINGLE POINT 58 10446 001 26 SHEAR BEAM LO8 LO9 L10 2050 3792 5514
41. ronments where high concentrations of salts are used on road surfaces undercoating is recommended 3M Universal Rubberized Undercoating 3M P N 8883 Spray undercoating when load cells are connected to electronics and fully assembled with bearing pads and brackets See Vulcan Load Cell Maintenance document 44 20006 001 for further details Fill unused holes in load cells with grease to protect against rust Never grease the inside of the connector Tipper Trucks Keep bearing surfaces greased preferably with a Moly Disulfide type of Check and grease the rear hinge pin pillow block assembly Check welds on upper load cell brackets IMPORTANT If a weld repair is required either remove the load cell or do not allow the temperature of the cell to exceed 140 F or 60 C Excessive heat can damage the strain gages located inside of the load cell Check all wiring for condition routing and protection Check meter for secure mounting and strain relief of wires Check system for functionality Review and address any driver concerns VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 5 37 Typical Western Logger Mounting 650 890 lb ft 3 1 000 1 400 Ib ft 2 LI TI O d ip A Co A A A CM A Figure 5 C Typical Hutch or Transpro Center Hanger Mounting 480 500 lb ft Torgue arm 300 350 Ib ft
42. s VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 62 CHAPTER 7 Truck Fully Loaded Truck Empty 5 Call Vulcan Customer Service again at 1 800 237 0022 to confirm the system calibration Final Calibration Channel A Cal Number Final Calibration Channel B Cal Number Final Calibration Numbers set Date VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 7 63 7 3 SYSTEM SPECIFICATIONS Load Cells Electrical Connector Voltage Required Material Operating Temp System Accuracy Vulcoder Environment Operating Temp 4 Wire Cable Black 2 Wire Cable Orange Connectors Voltage Input Required Voltage Output Required Signal Input Range Meter Display Cycle Speed Graduation Display Range Voltage Required Current Draw Protection Hookup Operating Temp Weight Installation Serial Output 350 Ohms nominal impedance 4 pin bulkhead military type 4 9 to 5 1 Vdc High grade alloy steel 40 to 140 degrees F Typical error less than 1 Full Scale of actual weight for operating temperature range and normal loading conditions Environmentally sealed electronics 40 to 180 degrees F Custom shielded 4 conductor polyurethane jacketed with drain wire 5 ft lengths standard Custom polyurethane jacketed industrial strength extension cord can be used in a pinch 45 ft length 4
43. st be in the down position and the body lift cylinder pressure must be relieved at the time of measuring for all methods The pressure relief valve should be engaged during weight measurements If the truck is not equipped with a pressure relief valve relieve the pressure manually In addition all packing should be done after the weight is recorded VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 18 CHAPTER 3 3 1 AXLE WEIGHT Vulcan Scales can be used to reduce overweight fines by measuring a vehicle s axle weight For refuse trucks the scales can indicate a weight on Channel B that should not be exceeded in order to keep the truck legal Load the truck close to the legal maximum according to a certified platform scale The number displayed on Channel B of the meter represents an approximate rear axle group weight and may be used as a reference weight to avoid exceeding the legal limit This reference weight may be different from the weight shown on the certified platform scale display Note Channel A does not represent steering axle weight V400 WEIGHT 34000 PLATFORM SCALE Figure 3 A Rear Axle Group Weight Channel B in Relation to a Certified Platform Scale 3 2 GROSS VEHICLE WEIGHT Gross Vehicle Weight Entire truck weight including fuel equipment personnel and payload In order to use the Gross Vehicle Weight method the Tare Weight for Channel
44. tch the meter display the number for period of 5 minutes If it wanders more than 200 lb 100 kg make a note of it Then clean and reconnect the left load cell If any one of the load cells wanders more than 200 Ib 100 kg perform the Leakage and Resistance tests refer to Section 6 2 1 and 6 2 3 If both of the load cells wanders more than 200 Ib 100 kg then the Vulcoder is faulty and needs to be checked refer to Section 6 2 4 Vulcoder Check Out Procedure VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 54 meter CHAPTER 6 If four load cells are connected per Vulcoder follow step 5c and 5d c For Vulcoders with 4 load cells disconnect the cables to all the load cells except the right front load cell Watch the meter display a number for a period of 5 minutes If it wanders more than 200 Ib 100 kg make a note of it d Disconnect right front load cell and reconnect right rear load cell Watch the meter display for 5 minutes If it wanders more than 200 Ib 100 kg make a note of it c Disconnect the right rear load cell and reconnect the left rear load cell Watch the display for 5 minutes If it wanders more than 200 Ib 100 kg make a note of it d Disconnect the left rear load cell and reconnect the left front load cell Watch the meter display for 5 minutes If it wanders more than 200 Ib 100 kg make a note of it If any one of the load cells wanders more than 200 Ib
45. ter POWER BUTTON Turns the meter on and off Also used to switch the display mode from pounds Ib to kilograms kg and to enter the Driver Lockout and Set Point modes on meter versions P8 0 and higher UP DOWN ARROW BUTTONS Used to increase or decrease the Cal Number and Tare Weight Also used to change the display from pounds 1b to kilograms kg adjust the Cycle Time and to enter the Driver Lockout mode on meter versions P8 0 and higher CYCLE BUTTON Used to view the weight on different channels and to adjust Cycle Time Also used in the Set Point and Driver Lockout modes on meter versions P8 0 and higher CAL BUTTON Used to view and adjust the Cal Number for a particular channel Also used in the Set Point and Driver Lockout modes on meter versions P8 0 and higher TARE BUTTON Used to view and adjust the Tare Weight and to change the display graduation from 100 lb to 10 Ib or 50 kg to 10 kg when the meter is locked on Channel A B Also used to access the Set Point mode on meter versions P8 0 and higher VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 1 LLL 9 1 4 ELECTRONICS INSTALLATION l Tape Vulcoder connectors prior to routing cabling to avoid contamination Mount Vulcoders on inside of truck frame rail or next to a structural member Mounting surface must be in an area protected from road or hauling debris 2 Route black cable to load cells Do not
46. the Power button Hold the Tare button until SP appears on the screen If a Set Point value has been previously entered it will appear on the display Ifa Set Point value has not been entered 0 will appear on the display 3 Use the Up and Down Arrow buttons to input the desired Set Point value To deactivate the Set Point feature enter 0 as the Set Point value 4 Press the Cycle button to store the Set Point value The meter will return to its normal operating mode Leave the meter on for 30 seconds to store the Set Point value in permanent memory Quick Reference Steps Deactivate Set Point To deactivate the Set Point feature enter 0 as the Set Point value in Step 3 above Verify Set Point Value To verify a previously entered Set Point Value refer to Step 2 in the above procedure VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC CHAPTER 3 17 CHAPTER 3 0 WEIGHT MEASURING METHODS The Vulcan Scale System can be used to measure weight by three different methods These methods are Gross Vehicle Weight Net Payload Weight and Net Pick up Weight The Net Pick up Weight can be determined by either the Continuous Tracking Method or the Isolated Pick up Method In addition to these methods Vulcan Scales can be used to determine Axle Weight as described in Section 3 1 Important Notice for Tipper Truck Operators To avoid weight measurement errors the forks mu
47. trim black cable to length 3 Important Check connectors to make sure they are clean and dry Turn meter off while making any wire connections Do not get moisture contact cleaner or any other substance inside of connectors 4 Check load cell connector coming from the Vulcoder for O ring Attach black cable connectors to bulkhead connectors on load cells Make sure they are finger tight plus an additional 1 8 of a turn with channel lock pliers The additional tightening is necessary to compress O ring preventing scale errors which can occur from moisture entering into the load cell connector Caution Do not over tighten the connectors as this can damage them 5 Route orange Vulcoder cable to cab Note On truck to trailer connection these wires may be routed using the existing truck trailer wire harness if two unused ungrounded wires are available Additionally you may follow the existing wire harness and use a separate connector of your choice between the truck and trailer 6 Find suitable location for the meter and install mounting bracket Secure cable so it does not obstruct other in cab equipment strain relief Vulcoder orange cable and cut to length Unplug terminal block from back of meter strip wires and make all wire connections to terminal block refer to Figures 1 E and 1 F Do not plug terminal block into meter at this time 7 Disassemble positive fuse holder red wire Connect fused power leads directly to b
48. ure in a load cell connector 4 Damaged cable between Vulcoder and load cell 5 Bad connection on green connector or broken wire or cable between meter and the Vulcoder 6 Faulty load cell What to Do 1 Using a voltmeter check the voltage at the back of the meter Refer to the required meter voltages in Section 7 3 System Specifications 2 Check the black 4 wire cabling between the load cells and the Vulcoder If the cabling is damaged contact your Vulcan dealer for Vulcoder repair 3 Measure the voltage between pins A and D of the Vulcoder connector If it measures less than 5 Volts make sure the Vulcoder cable is securely attached to the meter green plug and the length of the orange cable from the Vulcoder to the meter isn t longer than 100 ft Also check any truck trailer connectors in the Vulcoder signal cable 4 Before proceeding clean the load cell connector and cable connector with isopropyl alcohol and cotton swabs then dry with a hair dryer Do not overheat Reconnect and operate system for one day to see 1f the problem 1s fixed If the problem is not fixed continue to step 5 5 If two load cells are connected per Vulcoder follow the step 5a and 5b a Disconnect the cable to the right load cell Watch the meter display the number for a period of 5 minutes If it wanders more than 200 Ib 100 kg make a note of it Then clean and reconnect the right load cell b Disconnect the cable to the left load cell Wa
49. wn on V400 meter truck fully loaded Weight shown on V400 meter truck empty Example V 22 500 Ib 00 Ib 22 500 Ib 7 If the average difference between the certified scale and the meter is more than several hundred pounds you may want to adjust the Calibration Numbers If so proceed to Step 8 8 To determine the new Calibration Number for Channel A refer to the formula shown below Channel A New Cal Number Channel A Old Cal Number X P V Example Channel A Old Cal Number 2050 P 21 240 Ib V 22 500 Ib Channel A New Cal Number 2050 X 21 240 22 500 1935 9 To determine the Calibration Number for Channel B refer to the formulas shown below Note The Calibration Number for Channel B is different for a four load cell system and a six load cell system VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10016 001 Rev B STRESS TEK INC 32 11 CHAPTER 4 4 Load Cell System The Cal Number for Channel B should always equal the Cal Number for Channel A Channel B New Cal Number Channel A New Cal Number Example Channel B New Cal Number 1935 6 Load Cell System The Cal Number for Channel B should always be 1 85 times the Cal Number for Channel A Channel B New Cal Number Channel A New Cal Number X 1 85 Example Channel B New Cal Number 1935 X 1 85 3580 Record the new Cal Numbers below To enter the new Cal Numbers refer to the Procedure for Entering Starting Cal Numbers Section
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