SERVICE BULLETIN

Ref: AE/SB/081/2019 Date: 13.01.2020

Product: SLCM

Subject : Load cell installation & Operating procedure

Effective From : All SLCM
Group : Weighing System
Purpose: To facilitate the understanding of weighing system by Assembly,
Service engineers and to support the customer and operator of the vehicles on
accuracy to ensure customer satisfaction of batching process.

Mounting process of load cell cylinder on the Machine :

pg. 1 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 Contents:
1. Loading arm cylinder assembly with load cell
2. Load cell
3. Harness of load cell
4. Assembly process for load cell
5. Load cell technical specification
6. Connection pin details at junction box
7. Pre-Check after assembly
8. System configuration
9. Concrete batch controller
 Normal weighing
 Tare & Calibration procedure
 Tip-off Mode
10.Performance test report
11.Part number reference

1. Loading arm cylinder assembly with load cell

pg. 2 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 2. Load cell :( Part No: - L.065.010) Load cell is mounted on the loading
arm pin. As the bucket gets loaded, the force will be get applied on the
pin & in turn on the load cell.

3. Harness of load cell: (Part No:- L.032.110)

pg. 3 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 4. Assembly Process for load cell in cylinder:
1. Place the loading arm cylinder as mentioned in below pic.

2. Connect the load cell with supporting flange using M10 bolt (8 No’s).
Make sure proper tightness.
(Note: Make sure RHS and LHS Load cell assembly cable should face
towards cable routing hole to avoid the twisting of cable.)

3. Fix load cell assy. (Loading bracket & supporting bracket) to loading
arm cylinder supporting bracket. (Use M20 stud – 1 no’s).
4. Maintain 1 mm gap between load cell assembly and supporting
bracket on loading arm cylinder. (For accuracy measure through filler
gauge).
5. While mounting the loading arm cylinder with load cell on vehicle first
put cable through routing hole and then place the loading arm cylinder
to avoid any damages and twisting of cable

pg. 4 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 5. Load cell technical specifications:
SR.NO PARAMETER OUTPUT
1 Rated Output 2 mv/v
2 Gauge Resistance 700Ω ± 10Ω
3 Input Resistance 764Ω ± 10Ω
4 Output Resistance 700Ω ± 5Ω
5 Operating temp range 5-55°C
6 Excitation Volt 5V DC

6. Connection pin details at junction box:

SR. JUNCTION J1 (J1) COLOR CODE OF CABLES FROM JUNCTION J2 (J2) COLOR CODE OF CABLES
No. LOAD CELL ( LC1 & LC2) FROM CBC
1 EX1 + BLACK EX1 + BROWN
2 EX1- GREEN EX1- BLACK
3 LC1+ RED LC1+ WHITE
4 LC1- WHITE LC1- BLUE
5 SH1 SHIELD SH1 SHIELD
6 EX2 + BLACK EX2 + BROWN
7 EX2- GREEN EX2- BLACK
8 LC2+ RED LC2+ WHITE
9 LC2- WHITE LC2- BLUE
10 SH2 SHIELD SH2 SHIELD

pg. 5 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 7. Pre-Check after assembly:
Check as per the table below:
SI NO POINTS TO BE CHECKED VALUE

1 Check the gap between Load Cell and Loading Arm Supporting Bracket 1 mm (Symmetrically)

2 Check the Excitation Voltage at Junction Box Between (EX1+)&(EX1-) 5V DC

3 Check the Excitation Voltage at Junction Box Between (EX2+) & (EX2-) 5V DC

4 Check the continuity as per Junction 1 (J1) to Junction 2 (J2) Yes

5 Check the Input Resistance with Supply OFF at (EX1+) & (EX1-) in JB 764Ω ± 10Ω

6 Check the Input Resistance with Supply OFF at (EX1+) & (EX1-) in JB 764Ω ± 10Ω

7 Check the Resistance at LC1+ & LC1- at JB with No Load in Bucket 701Ω ± 3Ω

8 Check the Resistance at LC2+ & LC2- at JB with No Load in Bucket 701Ω ± 3Ω

pg. 6 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 Critical check points:
 The Stud connecting the load cell to the cylinder to be tightened
properly in order to maintain the gap between the load cell surfaces and
supporting bracket on loading arm cylinder at 1 mm.
 The wire from load cell to the CBC should not be damaged or tampered
anywhere.

8. System configuration:

pg. 7 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 9. Concrete batch controller (CBC 1.0.1) : ( Part No – L.350.025)
Setting up of CBC:
1. Normal Weighing:
ADC Test – CBC to be checked in diagnostic mode to see if the ADC counts are
normal for load cell.
Go to diagnostic mode testing and check as follow:
 Turn ON CBC by pressing GREEN Colour pushbutton switch and after
powering on the CBC press ‘ENT’ key within 5 seconds.
 Use ‘Down’ key and enter into ADC test.
 ADC test display corresponding counts with respect to sensor input in
digits as follows

 The load cell output signal (0-10 mv) can be checked with multi meter at
the junction box between LC1 + &LC1 and between LC2+&LC2. Make
sure the value should be same for both the load cell.
(Note: Value will be shown only when proximity sensor sense the 2nd (Big)
object. For no load, Multi meter reads ‘0’ mv)

pg. 8 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 2. Tare and Calibration procedure in concrete batch controller (CBC
V1.0.1) :
Tare – The empty bucket to be tarred at 2000RPM which will nullify the weight
of the bucket and dead weight (If present) effect in CBC for weighing.
Steps to tare:
 Keep bucket down and press TARE KEY in CBC.
 The display will show ‘TARE’.
 Raise loading arm & Pass it against the sensing big objects – up to prox.
LED on CBC glows.
 After passing second object the display will change and it comes out of
taring mode, it means taring completed.
Note: After taring, The Tare values should be cross verified that with no load in
bucket, CBC Should read zero kg in display. If not then do the tare again as
explained above.
Calibration – 4 Point Calibration to done at 2000rpm. For 2500 and 4500
models RPM to be checked through cluster. For 1000, 2000 and 4000 Models
RPM to be noted by tachometer by varying the speed by hand throttle for
calibration weight to be taken: 100, 300, 500, 700 Kgs.
Steps for Calibration:
 Keep bucket down and Load a known weight (to be calibrated) say 300
Kgs, in the bucket. Ensure weight is uniformly distributed.
 Press PGM/CAL. Now system will show CAL- xxx KG (xxx will show the
previously calibrated value) the last digit will be flashing.

pg. 9 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
  Enter the known weight to be calibrated by using INC / DEC to set each
digit. The digit under setting will be flashing. Press ENT KEY to shift to
the adjacent digit until the weight to calibrate is fully set on display. The
display will read CAL-300 KG.
 Raise loading arm & Pass it against the Sensing Objects. When the
Proximity switch passes the second Object display stops flashing and
calibration is completed & system automatically comes out from
calibration mode to weighing mode.
**The Above process has to be done with Caution, like Vehicle placing at flat
surface (1-2% Inclination), weighment placing (Symmetrically Distributed in
bucket), smooth movement of Bucket etc.

Checking of Calibration:
 Once the calibration is completed, go to Batching mode by pressing
PGM/CAL Key.

 Select the aggregates and weigh the system with the last calibration
point for about 4 cycles.
 Add few more weights (says 200 Kgs) and check for accuracy, if the
readings are within the acceptable range (Acceptable range 2%) then we
can conclude that the calibration has been successful.
 Test the weighing system to its maximum range and print the data &
Keep original copy for future references

pg. 10 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 Caution:
I. Do not calibrate when the vehicle is in the inclined condition. Always
calibrate with the vehicle in stationary condition.
II. Do not calibrate the system when the vehicle oil is cold, warm up the
vehicle with loading arm lifting and Drum rotation in full speed 10-20
minutes before tare and calibration.
III. To obtain accurate weight reading use hand lever accelerator control for
maintaining & lifting speed constant during tare and calibration
IV. Use known weight for calibration.
V. Place weight in bucket equally distributed (Symmetrically) to negate
centre of gravity effect.
VI. Do tare and calibration at 2000 rpm (i.e. recommended speed) speed
using hand lever accelerator.
(Engine throttle lever 90⁰ - Assuming approximately 2000 rpm/constant
loading)

3. Tip-off Mode:
The system has to be Tip-off calibrated for this mode as it is static weighing.
Tip off tare and calibration to be done at the time of installing.
 Tare – The empty bucket has to be brought to the Tip-off zone and
tarred.
 Calibration – Single point calibration is to be done at the tip-off zone
 ARGO 4000 and ARGO 2500 & ARGO 4500 : 400 – 500 Kgs
 ARGO 2000 : 160 – 260 Kgs

Working of Tip-off:
 When the operator notices the excess weight in the bucket after
weighing, he should press the Tip-off button and bring the Loading arm
to the big object position i.e. the light will flash in the CBC to indicate the
same.

pg. 11 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
  Now he can start tipping off the material by operating the Delivery door,
the instant weight in the bucket will be displayed on the CBC. (Note- The
previous lifted weight in bucket will be shown in same screen with *
marks).
 Once the operator press the Tip-Off, the cumulative value in CBC will
subtract the Previous lifted value from weighing and display last
cumulative value.
 When the required weight (5% Tolerance) is reached, operator can stop
the Tip-off and by pressing the enter button he can load the material
into the drum.

Thing that could affect the accuracy of weighing:

 Jerky movements while operating the vehicle.
 Improper Greasing of Loading arm and Bucket Pins.
 Improper tightening of the Load cell/ improper assembly of Load Cell.
 Inclination of the machine. Calibration of machine should not be done at
high inclination (1-2%).

Tip-off mode weighing:

1. Enter into batching mode.
2. Lift the bucket from bottom to top and observe recently lifted weight
will be read.

3. Press key to enter into Tip-Off mode. Observe the

Tip-off mode screen (screen a).
4. Bring back the bucket from top to the start of 2nd plate (Big plate middle
position) reference point, Decrease the weight from the lifted weight,
and observe the weight reading updated. For clear idea observe the
screen b.
5. Bring back the bucket from 2nd plate (Big plate) reference point to
bottom, to come out of Tip-Off mode.

pg. 12 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 
 Let’s consider during Tip-Off mode weight lifted is 400Kg. Screen a will
be displayed as soon we enter Tip-Off mode (Here XXX is the lifted
weight, for 400Kg it will be displayed as *400 400 400.
 Decrease 100Kg (If 300 Kg weight was required instead of 400 Kg) weight
from the lifted 400Kg weight Screen b will be displayed. The 300 in
middle is static weight and 300 at right side of screen is real time weight.
These weights will be updated for every 500 msec.

Repeatability test:
 With standard weights:
 Change in calibration:

1. The Engine RPM of the machine, placement of weights were kept

constant but calibration of the Machine was changed. It had no effect on
the accuracy of the system.
2. RPM changed:
The Calibration, placement of weights were kept constant but engine
RPM was varied. The Accuracy of the system remained the same.

pg. 13 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign
 3. Placement of weights altered:
The Engine RPM and Calibration were kept constant and the placement
of weight was altered. No Effect on the accuracy of the system.

 With Aggregates: Bucket was loaded with aggregates. 3 different

weights were loaded, the weight in the bucket was measured using
weigh bridge and compared with CBC readings.

10. Performance test result:

Calibration with known weights i.e. 450 Kgs % Variance 0.22%

@2000 rpm (done once at the start of test)
Test Condition Characteristics Result Location
1. Free Loading of Gravel to Accuracy of Variance 0-2 Kg Field
Drum from Gravel Heap weighing system on CBC
2. Aggregate Loading for 500
Cycles.
3. Verification with known
weight after every 5 0 0
cycles.

11. Part number reference:

SI. NO. Material Description Part No Qty. (No’s)

1 Load Cell L.065.010 2
2 CBC V1.0.1 with Tip-Off L.350.025.01 1
3 Cable Harness L.032.110 2
4 Junction Box 100010085000 1

pg. 14 of 14

Ajax Engineering Private Limited Bangalore – 560 058

Note: This is product improvement and not for subjected to campaign