Ravas SAFECHECK User manual

USER MANUAL – Safecheck
1
INSTALLATION AND USER MANUAL
RAVAS SAFECHECK
We would like to inform you about the fact that this RAVAS product is 100% recyclable on the basis
that the parts are processed and disposed off in the right manner.
More information can be found on our website www.ravas.com.
Rev.20181015
Printing/typographical errors and model changes reserved

USER MANUAL – Safecheck
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PLEASE RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
If you have any queries concerning the duration and terms of the guarantee, please contact your
supplier. We would also refer you to our General Sale and Supply Conditions, which are available on
request.
The manufacturer accepts no liability for any damage or injury caused by failure to follow these
instructions, or from negligent operation or assembly, even if this is not expressly stated in this
instruction manual.
In light of our policy of continuous improvement, it is possible that details of the product may differ from
those described in this manual. For this reason, these instructions should only be treated as guidelines
for the installation of the relevant product. This manual has been compiled with all due care, but the
manufacturer cannot be held responsible for any consequences of errors. All rights are reserved and
no part of this manual may be reproduced in any way.

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Table of contents
page
1. Introduction 4
2. Warnings & Safety measures 4
3. Principles 5
3.1 How the hydraulic system works 5
3.2 The reference height 5
3.3 Accuracy 5
3.4 Recommendations to increase the accuracy 6
4. Overview of the parts 7
5. Before setup 9
5.1 Capacity of the forklift truck 9
5.2 Maximum pressure in the hydraulic system 9
5.3 Power supply 9
5.4 Make the system free of oil pressure 9
5.5 The condition of the mechanical parts of the forklift truck 10
6. System Setup11
6.1 Installing the T-part 11
6.2 Mounting the sensor 13
6.3 Position of the indicator 14
6.4 Installing the indicator and the indicator bracket 14
6.5 Mounting the sensor cable 15
6.6 Remove any air from the hydraulic system 16
6.7 Placing stickers, marking the reference altitude 16
7. Settings 17
7.1 Determine the capacity of the truck 17
7.2 Interval setting 17
7.3 Change the delay-time 20
8. Calibration 21
8.1 Preparing for calibration 21
8.2 Correcting the zero point 22
8.3 Weight calibration (single point) 24
9. Bringing the system into service 27
9.1 Auto start 27
9.2 Using the reference height 27
9.3 The indicator 27
9.4 The touch panel of the Safecheck 28
9.5 Enter setpoint value (limit value) 28
10. The functions of the Safecheck 29
10.1 Correct zero point 29
10.2 Gross weighing 30
11. Power supply 32
11.1 Power supply by the trucks battery 32

USER MANUAL – Safecheck
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0
max 40°C
105°F
min -10°C
15°F
0
1. Introduction
This manual describes the installation and use of the Safecheck. The Safecheck is a hydraulic measuring
system for forklift trucks and stackers. The installer must be informed of the contents of this manual.
Follow the contents of the manual precisely. This manual should be kept on a safe and dry place. In case
of damage or loss the user may request a new copy of the manual from RAVAS.
2. Warnings & Safety measures
When installing the Safecheck please observe the instructions and
guidelines in this manual carefully. Always perform each step in sequence.
If any of the instructions are not clear, please contact RAVAS.
- All safety regulations that apply on the truck remain valid and unchanged;
- No weighing operations are allowed if any persons or objects are in the vicinity; around, under or
close to the load;
- Any modifications done to the system must be approved in writing from the supplier, prior to any
work being completed;
- It is the sole responsibility of the purchaser to train their own employees in the proper use and
maintenance of this equipment;
- Do not operate this unit unless you have been fully trained of its capabilities;
- Check the accuracy of the scale on a regular basis to prevent faulty readings;
- Only trained and authorized personnel are allowed to service the scale;
- Always follow the operating, maintenance and repair instructions of this truck and ask the supplier
when in doubt;
- RAVAS is not responsible for errors that occur due to incorrect weightings or inaccurate scales;
- A weighing is performed by slowly lowering the forks, this movement can be stopped at any time
by pressing the on/off button on the indicator.
.
Should you have any further questions after reading this manual, please contact us at:
RAVAS EUROPE B.V.
Toepadweg 7
Postbus 2023
5300 CA Zaltbommel
Nederland
Phone: [phone]
Fax: [phone]
Internet: www.ravas.com
Email: [e-mail]
IP65
READ
CAREFULLY

USER MANUAL – Safecheck
5
32"
80 cm
M1
3. Principles
3.1 How the hydraulic system works
The Safecheck is an hydraulic weighing system for forklift trucks and stackers. The load measurement
system measures the oil pressure with an oil pressure sensor.The pressure in the lifting system
depends on the load on the fork lift system. By measuring the oil pressure in the cylinder,
you will get an indication of the weight that you are lifting.
3.2 The reference height
To reduce the influence of the condition of the mast and the cylinder, the weighing is always
performed at the same height. To ensure this, stickers are placed on the mast and carriage plate to
clearly mark the reference height at which the weighing should occur.
First lift the forks past the reference point and then lower the load to the point where the stickers are
opposite each other. This results in the optimal accuracy.
3.3 Accuracy
Meassuring the oil pressure is a very precise job, but mechanical parts in the lifting mechanism
and the position of the mast can adversely affect the accuracy.
The friction/resistance of the roles with which it moves in the mast is a major influence on the
weighing. The resistance of the coils by dirt or bad bearings increase the inaccuracy caused by:
•internal leakage in the oil circuit;
•eccentric load of the forks (the load is not centered on the forks);
•the difference at slow or fast approaching of the reference altitude.
With more ' stick and slip effect ', there is less repeatability, so less accuracy. Repeatability means that
when you meassure the same weight in succesion, every time about the same weight appears in the
display.

USER MANUAL – Safecheck
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90°
M1
OK
OK
3.4 Recommendations to increase the accuracy
By using the following points, you can ensure that the system works as precisely as possible.
(see also chapter 8.1)
•By keeping the mast vertical during the load measurement
(an angle of 2 to 3 degrees has almost no influence);
•By putting the centre of gravity in the middle of the forks;
•Friction in mechanical parts such as the mast, the precision rollers and bearings influence the
accuracy of the weighing. Therefore it is important that these parts are in good condition:
- No local wear
- Clean
- Well lubricated mast and chains
- Regular maintenance
•Use the lift truck at least for 5 minutes or move the forks up and down several times (5x)
before the zero weighting and/or the first weighing is carried out;
•Weigh on a fixed height;
•Do not rise the forks to the reference point too fast. The best way is to raise the forks above
the reference point (the point where the stickers on the fork carriage and the mast are
opposite of each other) and then lower them down to the reference point. Do this slowly,
without sudden stop;
•When reaching the reference height, the weight will be fixated on the display. The weight is
not secured at loads below 20 reading steps;
•Make sure the system is relieved before beginning a new weighting;
•If the Safecheck sytem is installed on a new lifttruck, it is recommended that you perform a
recalibration after 3 months and 1 year.

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4. Overview of the parts
The Safecheck weighing system exists of two main parts:
1. Indicator
2. Sensor
The sensor has to be connected to a T-link on the hydraulic system of the forklift truck. The indicator,
the control panel, runs on 6 Volt batteries. On the drawing below you can find the parts of this sytem.
We recommend to have the installation of the sensor in the hydraulic system of the forklift
performed by an authorized lift truck dealer.
Type A: 1 central cylinder
Indicator
T-stuk
Sensor Sensorkabel
Hydraulisch
ventielblok
sensor cable
hydraulic
valve block
t-part

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T-stuk
Sensor
Sensorkabel
Hydraulisch
ventielblok
Indicator
Type B: 2 cylinders on both sides
hydraulic
valve block
sensor cable
t-part

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5. Before setup
Check the forklift truck on the following points before you begin the installation:
5.1 Capacity of the forklift truck
The Safecheck system can be installed on a forklift truck with a maximum capacity of 99 ton.
5.2 Maximum pressure in the hydraulic system
The Safecheck works optimally at an oil pressure up to 350 bar.
5.3 Power supply
The power supply of the indicator can be connected to the battery of the forklift. The most common
voltages for forklift trucks are 12, 24, 48 and 80 V. If the battery voltage is higher than 12 VDC, the
system demands a DC-DC voltage converter with an output of 12 Vdc.
5.4 Make the system free of oil pressure
The forklift truck has to be free of oil pressure. There are two ways to do this:
Option 1: Lower the forks to the ground in the lowest position and make sure the system is
without oil pressure, you can do this by tending the mast forwards. Make sure the
chain hangs loose.
Option 2: Raise the forks and place them on a pallet or an other stable object. Make sure the
system is without oil pressure by putting the cylinder in the lowest position.
Make sure the chain hangs loose.

USER MANUAL – Safecheck
10
90°
M1
OK
IP65
min -10°C
15°F
00
max 40°C
105°F
5.5 The condition of the mechanical parts of the forklift truck
After you have installed the Safecheck on the forklift truck, the weighing system will be part of the
truck. Especially the mechanical parts of the forklift truck, such as the mast, the mast rollers and the
ball bearings can influence the accuracy of the weightings.
Because of this it is important to keep the parts in good condition;
- make sure there is no local friction in the mast of the forklift;
- keep the system clean;
- make sure you get a good lubrication of the mast and the chains;
- take care for regular maintenance so that the condition of the system is constant;
- lifting and lowering of the forks should be as silent as possible.

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S19
1. 2.
6. System setup
6.1 Installing the T-part
- Ensure that there is no pressure on the high-pressure hose.
- The sensor is mounted with a T-piece in the high-pressure hose, between the valves and
the cylinder.
- The connection on the sensor is G¼” BSP male.
- Mount the T-piece so that the sensor and the cable connection are pointing downwards.
This will prevent air getting into the sensor.
- Protect the cable against moving, sharp or warm parts with the supplied protective cover.
Choose a place where you can mount the sensor:
- Mount the sensor in the pressure hose that steers the cylinder. In most cases there is one
cylinder which moves the carriage plate. The sensor is mounted as close to the cylinder
as possible.
- When the pressure hose splits to multiple cylinders, the sensor has to be mounted before
the split.
- Do not mount the sensor too close to the engine. Large differences in temperature can
influence the accuracy of the system.
- If the truck is used intensively, a piece of pipe or hose of ± 50 cm can be mounted
between the sensor and the T-piece. The sensor is sensitive to temperature differences.
If the moving oil becomes warm, the standing oil in this pipe or hose will remain cool.
The sensor will not be effected by temperature differences.
- Place the sensor close to the cylinder. There is often more room there and it is easier to
reach.
- Choose, if possible, a place to mount the sensor where there are the least steering and
safety valves between the sensor and the cylinder.
Type A: 1 central cylinder
Mount the T-piece into
the delivery pipe of the
truck near the cylinder
for the diversion of the
pressure to the
Safecheck.

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S19
1. 2.
Type B: 2 cylinders on both sides
Mount the T-piece into
the delivery pipe of the
truck near the cylinder
for the diversion of the
pressure to the
Safecheck.
Mount the T-piece so
that the sensor with
the cable connector is
facing down. This is to
prevent that there
remains air in the
sensor.

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S19
2.
1.
6.2 Mounting the sensor
The connector on the
sensor is G 1/4 "BSP
male.

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3
2
1
S13
1.
2.
S5
3.
6.3 Position of the indicator
6.4 Installing the indicator bracket and the indicator
The indicator should be easy
to operate and to read from!
S13
1.
2.
Indicator with RAM mounting bracket (option)

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2.
1.
3.
3.
6.5 Mounting the sensor cable
When mounting the cable, it is important that the cable is kept tidy and protected. Keep the cable out
of sight as much as possible, this keeps the system tidy and it minimizes the possibility of damage to
the cable.
It may be necessary to thread the cable through small openings, openings through which the 18mm
connector does not fit. In that case disconnect the cable at the indicator.
The system is supplied with a protective cover for the cable. This can be used when:
•the cable is near parts of the lift truck that become hot;
•the cable is mounted near moving parts.

USER MANUAL – Safecheck
16
32 "
90°
80 cm
1.
2.
6.6 Remove any air from the hydraulic system
6.7 Placing stickers, marking the reference altitude
Two stickers are supplied with this kit. One of the stickers is placed on the mast and one on the
carriage plate. The arrow stickers are used to show the reference height.
Attention:
•Make sure that the chauffeur can see the stickers;
•Make sure that there is minimal distance between the two arrows. The larger the distance, the
more difficult it will be to gauge the height accurately;
•Choose a practical height: not too high, because then lifting will take more time.
Moreover, it may be dangerous to lift heavy loads too high.
Bring the forks to maximum
height twice to remove any
remaining air from the
hydraulic system.
Attention:
In a dirty operating environment it is
better to mark the reference altitude
permanently.

USER MANUAL – Safecheck
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NET
kg/lb
NET
kg/lb
23 sec.
NET
kg/lb
7. Settings
7.1 Determining the capacity of the truck
The graduation of the indicator depends on the capacity of the lift truck.
The European directives for weighing systems state that the machine stickers should show the
producer, the capacity and the graduation. The kit contains a number of stickers with different
capacities and graduations.
•For a capacity of 5.000 kg the weight is shown in 50 kg steps;
•For a capacity of 10.000 kg the weight is shown in 100 kg steps.
Important !
If the lifting capacity of the forklift truck is different then the above-mentioned e.g. 1.500 kg or 3.000 kg,
a higher capacity should be chosen.For 1.500 kg the capacity will be 2.500 kg; for 3.000 kg it will be
5.000 kg.If you choose a setting and machine sticker with a smaller capacity, and therefore a smaller
graduation, then the measurement range and accuracy will not be in accordance with the
specifications.
The standard setting of the indicator is a capacity of 2.500 kg and a graduation of 50 kg. The following
procedure should be followed to change the settings.
7.2 Interval setting
2
3
4
1
Switch off the indicator
with the on/off key.
Push the
on/off key (do not
let go).
Confirm P02
The indicator shows the
graduation: 50 (50 kg)
50 for capacity 2.500 kg.
1 x
NET
kg/lb

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NET
kg/lb
NET
kg/lb
NET
kg/lb
NET
kg/lb
NET
kg/lb
6
7
8
5
9
10
Verander de waarden
met ˄en ˅ toetsen.
10 voor capaciteit
3000-5000 kg.
20 voor capaciteit
> 5000 kg.
Insert the value.
Change the values of
the reading steps with
the keys ˄ and ˅.
10 for capacity
3.000 – 5.000 kg.
20 for capacity
> 5.000 kg.
Use the ˄ and ˅ keys
and go to P05 for
setting the
appropriate capacity.
Confirm P05.
The indicator shows
the capacity 2500 kg.
5 x
1 x
NET
kg/lb
NET
kg/lb

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NET
kg/lb
NET
kg/lb
NET
kg/lb
3 sec.
12
13
11
Press Enter to return
to the normal
weighing mode.
Use the keys ∨and ∧
and change the value
to:
3 for 3.000 kg
5 for 5.000 kg
10 for 10.000 kg
Confirm the value of
the capacity.

USER MANUAL – Safecheck
20
NET
kg/lb
NET
kg/lb
23 sec.
NET
kg/lb
3 sec.
NET
kg/lb
NET
kg/lb
1x
NET
kg/lb
7.3 Change the delay-time
2
3
4
1
5
6
Turn the indicator
off.
Press on the
on/off button for
23 sec. until the
indicator shows
P01 (do not let
go)
Confirm with the

0/T

button.
The indicator now
shows P02.
Change the value to 3
seconds using the ˄
and ˅ button.
Delay time: 0–7 sec.
Depending on the type
of pallet truck.
Confirm with the 0/T
button. The indicator
shows a delay time 4 (sec.)
Push the 0/T
button for 3
seconds to
return to the
weighing mode.