Ravas RCS User manual

USER MANUAL – RCS
1
INSTALLATION AND USER MANUAL
RCS
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.20181031
Printing/typographical errors and model changes reserved

USER MANUAL – RCS
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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 errors or the consequences thereof. 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. Parts in the RCS-Kit 5
4. Principles 6
4.1 How the hydrualic system works 6
4.2 The reference height 6
4.3 Accuracy 6
4.4 Recommendations to increase the accuracy 7
5. Overview of the parts 8
6. Before installation 10
6.1 Capacity of the forklift truck 10
6.2 Maximum pressure in the hydraulic system 10
6.3 Battery voltage 10
6.4 Make the system free of oil pressure 10
6.5 The condition of the mechanical parts of the fork-lift truck 11
7. System Setup 12
7.1 Installing the T-part 12
7.2 Mounting the sensor 14
7.3 Position of the indicator 15
7.4 Installing the indicator and the indicator bracket 15
7.5 Mounting the sensor cable 16
7.6 Connecting the systems wiring 17
7.7 Remove any air from the hydraulic system 18
7.8 Placing stickers, marking the reference altitude 18
7.9 Placing the machine sticker on the indicator 19
7.10 Replacing the batteries of the indicator (before 2013) 20
7.11 Replacing the batteries of the indicator (2013) 21
7.12 Changing the batteries of the indicator (after XX/XX/2014) 22
8. Settings 23
8.1 Determine the capacity of the truck 23
8.2 Interval setting 23
8.3 Change the delay-time 26
8.4 Parameter settings 27
9. Calibration 29
9.1 Preparing for calibration 29
9.2 Correcting the zero point 30
9.3 Weight calibration (single point) 32
9.4 Weight calibration (multiple points) 35
10. Bringing the system into service 38
10.1. Turning the system on or off 38
10.2 Using the reference height 38
10.3 How can I weigh as accurately as possible? 38
10.4 The indicator 39
10.5 The touch panel 40
11. The Functions of the RCS-System 41
11.1 Correct Zero point 41
11.2 Gross weighing 42
11.3 Net weighing: automatic tare 43
11.4 Net weighing: manual tare entry 44
11.5 Totaling 47
12. Options 48
12.1 Power supply by the trucks battery 48
12.2 Printer (option) 51

USER MANUAL – RCS
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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 RCS. The RCS 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 RCS 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;
-Weightings should not be carried out if there are persons or objects near, next to or below
the forks/weighing last.
- 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

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3. Parts in the RCS-Kit
Sensor
Protective cover for the sensor cable
Indicator
Stickers to mark the reference
height
Penlight batteries
model AA
Machine stickers

USER MANUAL – RCS
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32"
80 cm
M1
4. Principles
4.1 How the hydrualic system works
The RCS 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.
4.2 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.
4.3 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 – RCS
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90°
M1
OK
OK
4.4 Recommendations to increase the accuracy
By using the following points, you can ensure that the system works as precisely as possible.
(see also chapter 10.1)
•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 (5 x)
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 to 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 RCS sytem is installed on a new lifttruck, it is recommended that you perform a
recalibration after 3 months and 1 year.
The hydraulic weighingsystem has a tolerance of max. 2% of the capacity of the weighingsystem.
At a capacity of 2500 kg that is a difference of 50 kg! When used properly the accuracy is usually
significantly higher.

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5. Overview of the parts
The RCS weighingsystem 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 forklifttruck. The indicator,
the controlpanel, 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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6. Before setup
Check the forklift truck on the following points before you begin the installation:
6.1 Capacity of the forklift truck
The RCS system can be installed on a forklifttruck with a maximum capacity of 99 ton.
6.2 Maximum pressure in the hydraulic system
The RCS works optimally at an oil pressure up to 350 bar.
6.3 Battery voltage
By default, the indicator is equipped with 4 AA batteries (6Vdc). Optionally, the power supply of the
indicator can be connected to the battery of the forklift. The most common voltages for fork-lift trucks
are 12, 24, 48 and 80 V. In cases where the battery voltages are higher than 12 VDC, the system
demands a DC-DC voltage converter with an output of 12 Vdc.
6.4 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 – RCS
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90°
M1
OK
IP65
min -10°C
15°F
00
max 40°C
105°F
6.5 The condition of the mechanical parts of the fork-lift truck
After you have installed the RCS on the forklift truck, the truck will be part of the weighing system.
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.
7. System setup
7.1 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 RCS.

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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 RCS.
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.
7.2 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.
7.3 Position of the indicator
7.4 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.
7.5 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 makes that the whole looks 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 it may be necessary to dismount the cable and the connector, you
have to dismount the cable at the indicator.
The system is supplied with a protective cover for the cable. This can be used where:
•the cable is near parts of the lift truck that become hot;
•the cable is mounted near moving parts.

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7.6 Connecting the system wiring

USER MANUAL – RCS
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32 "
90°
80 cm
1.
2.
7.7 Remove any air from the hydraulic system
7.8 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.

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7.9 Placing the machine sticker on the indicator
As described in the CE directive for weighing systems,
a machine sticker has to be applied to the
weighing system. The sticker shows the capacity
and the graduation. The stickers that are supplied
with the kit are suitable for different capacities.
Apply the correct sticker as shown:

USER MANUAL – RCS
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NET
kg/lb
M6
4 x AA
M6
7.10 Replacing the batteries of the indicator (before 2013)
The indicator is equipped with 4 AA batteries.
2
3
4
1
5
Replace the batteries as soon as the
LO-BA indication will blink.
As the LO-BA indication starts to flash
while printing (option), replace the
batteries.
Remove the M6 Allen screw with an
Allan key and open the housing of the
indicator.
Insert the new batteries in the housing.
Place the batteries correctly. Check the
polarity!
Remove the top side of the housing and
remove the batteries.
Fit the housing of the indicator and
tighten the M6 Allen screws with an
Allen wrench.