COMPULOAD Dynamic Series User manual

INSTANT WEIGHTPTY LTD
COMPULOAD CL2000MKII Dynamic Series MANUAL
Instant WeightPty. Ltd.
Postal Address
PO Box 2340
Midland DC WA 6936
Delivery address
47 Great Eastern Hwy
Bellevue WA 6056
Tel: [phone]
Email
[e-mail]
Internet
www.instantweighing.com.au

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Table of Contents
Note! _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 3
Warranty _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 4
Operating Principle _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Page 5
Weighing System Component Images _ _ _ _ _ _ _ _ _ _Page 5
Parts Supplied List _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Page 8
Safety Considerations _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Page 9
Installation Procedure _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _Page 10
1. Determine Hydraulic Fitting and Install Transducer_ _ _Page 11
2. Mount the Indicator and optional Printer_ _ _ _ _ _ _ _ Page 12
3. Attach the Boom Angle Sensor_ _ _ _ _ _ _ _ _ __ _ _ Page 13
4. Attach the Chassis Angle Sensor_ _ _ _ _ _ _ _ _ __ _ Page 14
5. Mount the Junction Board _ _ _ _ _ _ _ _ _ __ _ _ _ _ _Page 15
6. Route Transducer cable _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 16
7. Route Angle Sensors cables _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 17
8. Source Power _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Page 18
Diagrams _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Page 20
Setup and Calibration _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 36
About the Compuload 2000mk2 Weighing System_ _ _ _ _Page 43
Schematic _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Page 44

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NOTE: - These basic installation instructions are given
based on the installer having previous experience in
the servicing and maintenance of machinery. General
safety precautions should be undertaken similar to
carrying out maintenance on this type of machinery.
Inexperienced personnel should not undertake this
task if they are unsure of the safety precautions
necessary

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WARRANTY COMPULOAD CL2000MKII
THE COMPULOAD CL2000MKII HAS NO USER SERVICEABLE
COMPONENTS INSIDE DO NOT ATTEMPT TO DISMANTLE THE UNIT AS
THIS WILL CAUSE YOUR WARRANTY TO BECOME NULL AND VOID.
INSTANT WEIGHTPty. Ltd. warrants the COMPULOAD Series
CL2000MKII load weighing gauge and any optional equipment to be free of
defects in workmanship and material for aperiod of twelve (12) months from
date of dispatch or installation, (whichever is applicable)
This Warranty only applies provided the COMPULOAD CL2000MKII and
accessories are used in accordance with the recommendations of
INSTANT WEIGHTPty. Ltd. under normal use and reasonable care.
The warranty does not cover damage in any way whatsoever including transit
damage. The warranty does not cover malfunction or failure resulting from
misuse, neglect or abuse.
The warranty immediately becomes void should any repairs, alterations or
modifications are carried out or attempted to be carried out by other than
INSTANT WEIGHTPty. Ltd.
The warranty is not transferable and applies only to the original purchaser
unless authorised by INSTANT WEIGHTPty. Ltd.
The warranty does not include travel expenses should a factory engineer or
representative be required to preform repairs on site.
At the option of INSTANT WEIGHTPty. Ltd. any faulty units or components
will be repaired or replaced free of charge whilst within the warranty
period providing the unit or component is returned to our premises with
freight pre-paid.
Our factory engineers will offer all possible assistance to rectify any difficulties
experienced in the field. The larger majority of problems can be overcome by
telephone. Please contact our office prior to forwarding any units or
components for attention
NOTE Our carrier does not accept responsibility for loss or damage in transit.
Should transit or freight loss or damage insurance be required it must be
indicated on your order and the cost of such insurance will be charged
accordingly.

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OPERATING PRINCIPAL
The COMPULOAD CL2000MKII Dynamic weighing system works by
measuring the pressure in the lift side of the hydraulic cylinders lifting
the arms. It compares this pressure to the speed that the arm is lifting
the load at to determine the weight of the load.
The speed is measured by angle sensors fitted to the arm and the
frame. The pressure is measured by the pressure sensors
(Transducer). The PRESSURE SENSOR (TRANSDUCER) and
ANGLE SENSORS are connected to the INDICATOR via the
JUNCTION BOARD.
INDICATOR
PRESSURE
TRANSDUCER

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ANGLE SENSOR - CHASSIS
ANGLE SENSOR - BOOM

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JUNCTION BOARD

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Parts Supplied List
•C2000mk2 indicator with RAM mount
•Junction Board with 4 connectors
•Angle Sensor x 2
•Pressure Transducer x 1 with Superseal connector and ¼”BSP
adapter
•Cable: Indicator / Printer - Junction Board
•Cable: Junction Board - Transducer
•Cable: Boom Angle Sensor (with CAN bus terminator) - Junction Board
•Cable: Chassis Angle Sensor - Junction Board
•Cable: Power - Junction Board
•4-Pin CAN Plug Pack
•Hydraulic fitting pack
•Power supply pack
•Adhesive pack
•Cable Tie Pack
•Cable Mount Pack
•Installation Manual

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Safety Considerations
Extreme Caution should be used when accessing the machine
hydraulics. This should only be undertaken by experienced technicians
who are familiar with machine hydraulics.
Ensure the main boom lifting arms are fully lowered to the ground prior
to accessing the hydraulic lifting circuit or removing any hydraulic
fittings.
Remove any excess hydraulic pressure in the lifting circuit by
exercising the lift lever fully forward with the machine turned OFF.
Refer to the machine manual if in doubt.
Remove the hydraulic tank cap to remove any pressure inside the tank.
Slowly remove any “easy to get at” hydraulic fitting in the lifting circuit
very carefully to check for excess pressure.
REMOVING OR LOOSENING ANY HYDRAULIC HOSES WITHOUT
RELEASING THE PRESSURE CAN RESULT IN SERIOUS INJURY OR
DEATH. IF IN DOUBT ENGAGE THE SERVICES OF A HYDRAULIC
SPECIALIST.
DO NOT, UNDER ANY CIRCUMSTANCES, WORK or WALK UNDER
UNSUPPORTED LIFTING ARMS. DOING SO CAN RESULT IN SERIOUS
INJURY OR DEATH.

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INSTALLATION PROCEDURE FOR THE COMPULOAD
CL2000MKII
1- Determine hydraulic fitting and install Transducer
2- Mount The Indicator / printer
3- Attach the Boom Angle Sensor
4- Attach the Chassis Angle Sensor
5- Mount the Junction Board
6- Route Transducer cable
7- Route Angle Sensors cables
8- Source power
9- Setup and calibrate the system

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1. Determine Hydraulic Fitting and Install Transducer
Safety!
•Deenergize any sources of energy. Isolate battery. Lower
implement to ground and relieve hydraulic oil pressure. NB:
removing hydraulic oil tank cap is not sufficient!
•Use a stand if the boom needs to be raised of the ground to allow
access.
•Confirm isolations are effective.
Steps
1. Locate lift side of the hydraulic cylinder. (Piston end) [see diagram 1]
2. Locate pipe connected to lift side of hydraulic cylinder
3. Follow the pipe all the way back to the control valve, noting all the
connection points along the pipe/hose.
4. Determine the best connection point to fit the transducer via tee block.
[see diagrams 2-6]
5. If no connection point is viable, determine best fitting to remove to be
drilled and taped for direct connection. (See Direct Connection this
page)
6. Open the connection and determine type and size of fitting. Contact
Instant Weight Pty Ltd for help identifying and supplying correct tee
block to suit. Take photos of connection and measure any threads etc
and send to Instant Weight Pty Ltd. We stock a full range of fittings.
7. Install tee block or direct connection and attach transducer.
8. Ensure all connections are tight and test for leaks.
9. Optional - bleed transducer by SLIGHTLY loosening transducer connect
when boom is raised just of the ground. Re-tighten connection
once bubbles in oil disappear.
Considerations
•Choose a location easy to access
•Mount transducer in a way that prevents debris hitting it.
•Consider how you will route the cable to the transducer.
•Does the connection point move during operation?
•Vibration or heat sources (exhaust etc)
•Are there any test points / pilot lines coming off the pipe which may be
easier?
Direct Connection [see diagram 7,8]
1. Remove the fitting to be tapped.
2. Drill an 8.5mm hole.
3. Tape to 1/8bspt.
4. Thoroughly clean swarf from fitting.
5. Install supplied 1/8”bspt male - 1/4“bsp female swivel fitting.
6. Reinstall fitting to pipe.
7. Attach Transducer using ¼” bspt adapter.
8. Check for leaks and bleed.

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2. Mount C2000MKII Indicator and Optional Printer
Safety!
•Do not restrict or impair operator vision or controls.
•Do not drill, weld, or cut R.O.P.S / F.O.P.S
Steps
1. Locate a suitable location - normally within easy reach of the
operator’s right hand.
2. Determine how to mount the supplied RAM mount to the machine.
[see diagram 9]
3. Mount RAM mount to machine.
4. Mount indicator to RAM mount.
5. Connect the Indicator cable to the indicator and route the cable to
the Junction Board. 4-pin connector wiring [see diagram 26]
Considerations
•A bracket can be bolted onto a lock striker plate or door frame
aperture.
•Sometimes mounting points are supplied within the cabin for
brackets.
•A “clamp” type bracket may be required on some model loaders.
This clamps onto the hand rails in the machine. Instant Weighing
has these mounts in stock.
•Use the supplied Sika 252 adhesive to attach a flat plate to the
R.O.P.S. and mount off that.
•When mounting printers, consider mounting the printer above
the indicator. This keeps the indicator within reach of the
operator.

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3. Attach the Boom Angle Sensor
Safety!
•Support the boom if working on it while raised.
Steps
1. Select the position on the boom to mount the sensor. [see diagram
10,11]
2. Mark outline of sensor plate.
3. Tape outline. [see diagram 12]
4. Roughen surface with Scotch pad (red). [see diagram 12]
5. Roughen sensor plate.
6. Thoroughly clean surfaces with clean, lint free cloth using zero residue
cleaner. Methylated Spirits, Isopropyl Alcohol etc.
7. Apply Sika 252 to sensor plate, leaving gap for air to escape. [see
diagram 13]
8. Press plate onto surface until adhesive is pressed out from each edge.
[see diagram 14]
9. Scrape away all excess adhesive using supplied plastic scraper and
rag. Remove tape. Use Methylated Spirits to clean uncured Sika 252.
[see diagram 15,16]
10.If required, support sensor with tape until adhesive cures in a few
hours. 12-24 hours for full cure. [see diagram 17]
Considerations
•Consider how the cable will be run to the sensor. Use supplied cable
mounts if needed. [see diagram 18] Use Sika 252 to attach them to
boom. Follow same preparations procedures as boom sensor.
•The Lift Arm angle sensor is mounted on either the inside or outside of
the left-hand side or right-hand side boom. The position of the sensor
will be programmed in the settings. The position of the boom angle
sensor is best determined by the ability to position it in a protected
position that will be away from falling objects or similar that can damage
the sensor. Mounting under a steel bracket that may support hydraulic
hoses or similar is recommended.
•With the lifting arms horizontal (pin on bottom of bucket and pin
connecting the chassis to the boom level with the horizon), [see diagram
19] mount the Lift Arm angle sensor with the connectors pointing down.
Connectors will be at approx 45 degrees with arms horizontal. [see
diagram 10,11]

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4. Attach the Chassis Angle Sensor
Safety!
•Support the boom if working on it while raised.
Steps
1. Select the position on the chassis to mount the sensor. [see diagram
20-23] For articulated loaders mount the chassis sensor forward
of the articulation point.
2. Follow the same procedure as boom angle sensor to glue sensor to
chassis. [page 13]
Considerations
•The Chassis Angle Sensor is mounted flat on any solid flat surface of
the main chassis of the loader.
•The cable for the Chassis Angle Sensor should be facing the rear of the
loader.
•A typical mounting for the Chassis Angle Sensor position is near where
the junction board is located.

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5. Mount the Junction Board
Safety!
•Support the boom if working on it while raised.
Steps
1. Select the position on the chassis to mount the Junction Board.
2. Follow the same procedure as boom angle sensor to glue sensor to
chassis.
Considerations
•The Junction Board is the hub where the sensor wiring, power wiring,
and wiring from any other options will also terminate.
•All cables must be in range of the junction board. Plan ahead.
•Run the indicator cable to a position to where the junction board is
mounted.
•In most articulated loaders, the Junction board will be mounted at the
front section of the machine.
•The Junction Board mounting bracket is normally glued to the side wall
of the chassis near the main hydraulic control valve. In other machines,
the junction board can be mounted beneath the cabin, behind the cabin
or any other relatively safe place.
•The junction board should be mounted in a position where it is
protected. It should not be mounted where it will be subjected to high
pressure water.
•The junction board can be removed from the mounting plate and
mounted using the mounting holes.

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6. Run the Transducer cable from the Junction Board
and Connect to Transducer
Safety!
•Support the boom if working on it while raised.
Note: The second transducer is optional. Some applications
benefit from the second transducer.
Steps
1. Connect the cable to the IO Convertor on the Junction Board.
1. Connect the other connector to the 6 Port CAN Bus on the Junction
Board. Use the wiring layout at the end of this manual to determine
which port to connect to.
2. Run the cable to the Transducer. Ensure to follow existing
cables/hoses all the way.
3. Allow some excess and trim the cable to length.
4. Attach the Superseal connector to the cable. [see diagram 24]
5. For instructions how to assemble the transducer connector: [see
diagram 25]
6. Connect to the cable to the transducer.
Considerations
•The Junction Board is the hub where the sensor wiring, power wiring,
and wiring from any other options will also terminate.
•All cables must be able to reach the junction board. Plan ahead.
•Run the indicator cable to a position to where the junction board is
mounted.
•In most articulated loaders, the Junction board will be mounted at the
front section of the machine.
•The Junction Board mounting bracket is normally glued to the side wall
of the chassis near the main hydraulic control valve. In other machines,
the junction board can be mounted beneath the cabin, behind the cabin
or any other relatively safe place.
•The junction board should be mounted in a position where it is
protected. It should not be mounted where it will be subjected to high
pressure water.
•The junction board can be removed from the mounting plate and
mounted using the mounting holes directly.

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7. Run the Angle Sensor Cables to the Junction Board
Safety!
•Support the boom if working on it while raised.
•Use ladders and safety steps to avoid falls.
Steps
1. Connect the cable to the Boom Angle Sensor and route the cable to
the Junction Board. Use the glue on mounts if no tie down points are
available [see diagram 18].
2. Connect the 4-pin connector [see diagram 26] and attach the connector
to 6 Port Can Bus. [see diagram 28]
3. Ensure the CAN terminator plug is connected to the other port on
Boom Angle Sensor. [see diagram 10]
4. Connect the cable to the Chassis Angle Sensor and route the cable to
the Junction Board.
5. Connect the 4-pin connector [see diagram 27] and attach the connector
to 6 Port Can Bus. [see diagram 28] Allow some excess and trim the
cable to length.
Considerations
•When routing cables through the articulation ensure that only one
pipe/hose/harness is followed the entire way from fixed point on the
front half to fixed point on the rear half otherwise the cable will be
damaged.
•All cables must be able to reach the junction board. Plan ahead.
•Place cables ties at a maximum of 300mm apart.
•Keep cables away form heat sources and electric noise sources like
high current relays and solenoids and generators.

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8. Source Power
Safety!
•Isolate battery before connecting to power.
•Confirm isolation.
•Support the boom if working on it while raised.
•Use ladders and safety steps to avoid falls.
Steps
1. Locate an ignition switching source. Also called accessories.
2. Locate a suitable ground point near the ignition source.
3. With the key turned to Accessory using a test light, or multimeter if no
test light is available, measure the voltage between the ignition source
and the ground. C2000MKII needs 12-24Volt DC. System draws max
5amps with a printer.
4. With the key off confirm no voltage is present.
5. Isolate the machine
6. Connect the fuse holder supplied to the ignition source. Connect the
brown wire from the power lead to the other end of the fuse wire.
7. Connect the white wire from the power lead to the ground source.
8. Connect the power lead to the 6-Port Can Bus Rail. [see diagram 28]
Considerations
•Easily accessed ignition source is on the back of the key or back of the
fuse panel.
•A good ground is essential. Causes of bad grounds can be painted
panels or plastic panels. Make sure the ground source is a bolt
connected to bare metal. Run a tap through the thread if required to
remove any paint.
•All cables must be able to reach the junction board. Plan ahead.
•If direct battery power is connected, a ON/OFF toggle switch can be
installed.

Intentionally blank

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DIAGRAMS
Diagram 1 Diagram 2