SEBU7012-08

July 2003

Operation and
Maintenance
Manual
Payload Control System
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents
Foreword ................................................................. 4

Operation Section
Payload Control System Features .......................... 6

System Setup Options ............................................ 8

System Operation ................................................. 17

Reference Information Section

Reference Materials .............................................. 25

Index Section
Index ..................................................................... 26
4
Foreword
Foreword
Literature Information
This manual should be stored in the operator’s
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your machine. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your
machine, or this publication, please consult your
Caterpillar dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to
keep the engine and machine systems operating
correctly. As the heavy duty off-road diesel engine
owner, you are responsible for the performance
of the required maintenance listed in the Owner
Manual, Operation and Maintenance Manual, and
Service Manual.
 5
Foreword

It is prohibited for any person engaged in the 3. Check Character (character 9)

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or
render inoperative any emission related device or
element of design installed on or in an engine or
machine that is in compliance with the regulations
(40 CFR Part 89). Certain elements of the machine
and engine such as the exhaust system, fuel
system, electrical system, intake air system and
cooling system may be emission related and should
not be altered unless approved by Caterpillar.
Machine Capacity
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Machines and generator sets produced before First
Quarter 2001 will maintain their 8 character PIN
format.
Components such as engines, transmissions,
axles, etc. and work tools will continue to use an 8
character Serial Number (S/N).

Additional attachments or modifications may exceed

machine design capacity which can adversely
affect performance characteristics. Included would
be stability and system certifications such as
brakes, steering, and rollover protective structures
(ROPS). Contact your Caterpillar dealer for further
information.

Caterpillar Product Identification

Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) will change from 8
to 17 characters. In an effort to provide uniform
equipment identification, Caterpillar and other
construction equipment manufacturers are moving
to comply with the latest version of the product
identification numbering standard. Non-road
machine PINs are defined by ISO 10261. The new
PIN format will apply to all Caterpillar machines and
generator sets. The PIN plates and frame marking
will display the 17 character PIN. The new format
will look like the following:

g00751314
Illustration 1

Where:

1. Caterpillar’s World Manufacturing Code

(characters 1-3)

2. Machine Descriptor (characters 4-8)

6
Operation Section
Payload Control System Features
Operation Section
Payload Control System
Features
i01899694
General Information
SMCS Code: 7494
Introduction
The Payload Control System (PCS) is an advanced
electronic computer system. The system will provide
an accurate weight of the material that was loaded
by your wheel loader. Using the PCS will ensure
proper weights for the customer. The PCS will
prevent the risk of overloading a truck.
The PCS will interface with an IBM compatible
personal computer. This will provide the capability
to analyze productivity.
This manual is intended as an operator’s guide to
the basic functions of the Payload Control System.
Read this manual completely before using the
Payload Control System.
Illustration 2 g00447811
Payload Control System (1).
Getting Started
The Payload Control System should be properly
installed in the wheel loader. The PCS should
be calibrated for the wheel loader. See Service
Manual, SENR6614, “Payload Control System
(PCS)” for information on installation and calibration
procedures.
A brief description of the calibration procedure
is provided in this manual. See Operation and
Maintenance Manual, “System Calibration” for
information on the calibration procedure.
i01899846
Weighing Material
SMCS Code: 7494
Note: In order to obtain an accurate weight, make
sure that the pins are lubricated on the lift arm
linkage. The hydraulic oil is warmed up to the
normal operating temperature.
In order to weigh a bucket of material, lift a loaded
bucket. The bucket should be racked back fully.
Move the lift lever smoothly into the full detent
position. The loaded bucket will be weighed as the
bucket travels through the upper lifting range. As
the bucket is being weighed, the top line of the
display will show “WEIGH”. The bottom line will
show dashes.
When weighing is completed, the top line will show
the weight of the bucket. If the operator lifts a
significantly larger load that exceeds the calibration
weight by 50%, the message “MAX” will appear
on the display. If this message appears, dump
some material from the bucket and lift again. If the
“MAX” message appears repeatedly, recalibration
is required.
See Operation and Maintenance Manual, “System
Calibration” for information on recalibration. The
weight will be displayed in the selected units. The
possible units are shown below.
• US Tons
• Metric Tons
• Lb X 1000
The bottom line of the display will show the
accumulated weight of the truck. This weight is from
the last time “STORE” or “CLEAR” was pressed.
The rpm of the engine should be kept constant
through the lifting range. Avoid directional shifting or
harsh turning in order to ensure accurate weighing.
Note: If the lift system has been idle for more than 4
hours, the error message “LIFT BUCKET 10 TIMES”
will appear on the display when the operator lifts
the bucket.
See Operation and Maintenance Manual, “Normal
Weighing Mode” for information on the error
message.
 7
Operation Section
Payload Control System Features

i00879134 Next Function Key

General Keypad Operations
SMCS Code: 7494
You should understand the basic usage of the
keypad before operation. This will help you use
the Payload Control System for the first time. The
numeric keys serve two purposes.
(1) Provide the entry of data.
(2) Provide access to other functions.
See Operation Manual, “Keypad Modes and
Functions” for more information on the available
functions.
Clear Key
The “CLEAR” key is used for three purposes.
• The “CLEAR” key is used in order to erase an
entry.
• The “CLEAR” key is used in order to exit from
a function.
• The “CLEAR” key is used in order to correct a
numerical error that was made.
Press the “CLEAR” key in order to clear a mistake
that was made during the entry of data. Enter the
correct information or press the “CLEAR” key again
in order to exit from the current menu.
The “NEXT FUNCTION” key is used in the setup
and service modes. This key is used in order to
advance to additional functions.
Menu Basics
Select a function from the menu. The title of the
function is shown on the display. The current
function is then displayed on the top line and
underlined.
Press the “SCROLL” key. All of the available
functions will be shown. Only the currently selected
function will be underlined.
Press the “SCROLL” key in order to select a new
option. Press the “SCROLL” key until the desired
option is shown on the top line. When the desired
option is shown, press the “STORE” key. The
function will be shown for one second. The function
will be underlined. This will be shown before the
system advances.
Pressing the “NEXT FNCTN” key will advance the
system. The system will advance only if the current
selection is the active selection. Press the “CLEAR”
key if the current selection is not active. Press the
“CLEAR” key in order to return to the currently
active selection.

“Store” Key
The “STORE” key is used in order to complete
functions. The “STORE” key is used in order to
complete the entry of numerical data. The “STORE”
key is used in order to complete the selections of
menus. The “STORE” key will also store the data in
permanent memory.

Press the “STORE” key in order to complete a

numeric entry when the display shows your desired
entry. This will complete the current function. The
system will then proceed to the next step.

“Scroll” Key
The “SCROLL” key is used when multiple selections
are available. Press the “SCROLL” key in order to
advance to the next option. The display is reset
to the top of the menu if the end of the menu is
reached.
8
Operation Section
System Setup Options

System Setup Options

i01899921

Operator Setup Functions

SMCS Code: 7494
 9
Operation Section
System Setup Options

g00988242
Illustration 3
10
Operation Section
System Setup Options

Note: The underlined settings for each menu item • Spanish

reflect the factory default setting.
• Swedish
Press the “SETUP” key or press the “NEXT FNCTN”
key. This will activate the menu that is used for • Norwegian
setup. Press these keys from the normal weigh
mode or from the standby modes. All of the setups “Scroll Speed” Menu
that are described are stored in permanent memory.
The setups will remain active until the setups are The menu allows the operator to select the scroll
changed. speed for the message display. The scroll speeds
are listed below.
Setup for the Operator
• Slowest
A security password is not required for changing
the setup. • Slow

ID of the Operator • Normal (Default)

This is an optional numerical input. This allows • Fast

the operator to enter a number that is used for
identification. This information is recorded with the • Fastest
information for the truck. This information is also
printed on the “tickets” for the trucks. This function i01900143
expects a numeric input from 0 to 99999. This
function is turned on from the setup of the owner. Owner Setup Functions
See Operation and Maintenance Manual, “Owner
Setup Functions” for more information. SMCS Code: 7494

“Units” Menu The owner setup menu and the owner setup
functions are located at the end of the operator
This menu allows the selection of the units that are setup menu. These menus are protected by a
used for the weight on the display. There are three password. The owner setup menu has functions
different units that are available. that will be set one time in most cases. This is
usually done during the delivery of the machine.
The functions need to be set for the date and the
• US Tons time. These functions are the first options after the
password.
• Metric Tons
• Lb X 1000 Password
US Tons is the default setting. If “tickets” are printed, Access to the owner setup functions is protected
the “tickets” will be printed in the same units that by a password.
are on the display.
Note: The default password is 12345. This is the
“Language” Menu password that was set at the factory. Enter the
password and press the “STORE” key in order to
The language for the display is controlled by access the owner setup functions. The password
this function. There are eight languages that are can be modified to a specific password for the
available. owner.

• English (Default) Setting the Time and the Date

• German The month and the day will be displayed on the top
line. The hour and the minute will be displayed on
• French the bottom line. The digits for the hour will flash.

• Portuguese Press the digits for the hour or press the “SCROLL”
key. This will allow you to advance one hour at a
• Italian time. Press the “STORE” key in order to set the
hours.

Note: The time is always set in a 24 hour period.
The time that is used is military time. 1:00 pm =
13:00 hours
The digits for the minutes will flash. Press the digits
for the minute or press the “SCROLL” key. This will
allow you to advance one minute at a time. Press
the “STORE” key in order to set the minutes.
The abbreviation for the month will flash. Press the
“SCROLL” key in order to scroll through the months.
Then press the “STORE” key.
The day will flash. Press the digits for the day or
press the “SCROLL” key in order to advance one
day at a time. Press the “STORE” key in order to
set the date.
The year will flash. Enter the year and press the
“STORE” key.
Note: The year must be between 1995 and 2176.
Use the clock set function in order to advance the
year from 1900 to 2000. This should be done as
soon as possible after 31 December 1999. This is
required for software package 2.06 or earlier.
Press the “NEXT FNCTN” key in order to skip setting
the time. If only the hours need to be set use the
following procedure.
1. Set the hour.
2. Press the “STORE” key.
3. Press the “NEXT FNCTN” key.
Setting the Weigh Range
If the current range is acceptable, press the
“NEXT FNCTN” key in order to skip this operation.
This function allows you to customize the weigh
range for the particular application. It may be
preferable to lower the default weigh range for
loading hoppers. The default weigh range is 50% to
80% of the height of the lift arm. This range works
well in most cases.
The message “SHOW WEIGH BEGIN-STORE” will
be displayed on the top line. The current height of
the lift arm is displayed on the bottom line. The
current height of the lift arm is displayed in percent
of maximum lift height X 10. If the arms are above
the current setting, the bottom line will flash. Press
the “STORE” key in order to temporarily save the
location of the new beginning. Press the “STORE”
key in order to advance to the setting for the weigh
ending position. The arms must be above 15% for
the weigh begin setting.
11
Operation Section
System Setup Options
The message “SHOW WEIGH END-STORE” will
be displayed until the lift arms are moved from
the current range. The height of the lift arm will be
displayed on the bottom line. The bottom line will not
flash when the lift arms are above the current range.
If the selected range is not valid, an error message
that describes the problem will be displayed. The
procedure that is used for setting the weigh range
will be started again. No permanent change will be
made until both of the settings have been stored.
There are three limitations on the weigh range.
(1) The total range of at least 15% of the travel of
the lift arm is recommended.
(2) The initial setting of more than 15% is
recommended.
(3a) The setting of less than 95% is recommended
for the end.
(3b) The setting of at least 30% or more is
recommended for the weigh range.
Note: The person that is setting the range should
understand the negative effects of improperly
setting the weigh range. The weigh range should
be in the area of the smoothest operation.
Setting the weigh range too low
Setting the weigh range too low may cause
excessive reweigh indications and poor weighing
accuracy. This is because of situations of manual
breakout. This is also due to shifting the transmission
from reverse to forward.
Setting the weigh range too high
Setting the weigh range too high may cause
excessive reweigh indications. Do not set the weigh
end at the maximum lift height. This will cause a
reweigh.
Height Considerations
The distance of the lift range from the bottom to the
top should be kept as big as possible. This will allow
changes in the lifting technique of the operator.
Setting a narrow weigh range
Setting a narrow weigh range may lead to poor
accuracy. This is due to the limited number of data
samples.
Note: A weigh range of at least 30% or more is
recommended.
12
Operation Section
System Setup Options
Machine Identification
This option will allow the input of an identification
number. This number will be printed on all tickets.
This number will be used in order to identify data
that is loaded to another computer.
Tickets Menu
This menu enables the selection of either zero, one,
two, or three tickets to be printed automatically
when the “STORE” key is pressed. Even if the zero
tickets is selected, single tickets can still be printed
by pressing the “PRNT” key after the “STORE” key
is pressed and before any additional weights are
taken.
AUTO Truck ID
This menu enables the automatic operation of the
Truck ID when the “STORE” key is pressed. This
menu also disables the automatic operation of
the Truck ID when the “STORE” key is pressed.
When the menu is enabled, the operator will be
automatically prompted for the identification of the
truck that was just loaded. When this option is
disabled, identification of the truck must be entered
before storing the Truck weight.
Operator ID
This option allows you to input an identification
number of an operator. The number can be from 0
to 99999. This number will be printed on all tickets
if this number is not zero.
If this option is activated, the Identification of the
Operator is automatically enabled when the machine
is started. The identification of the operator is also
the first mode in the Operator Setup Functions.
Automatic Identification of the
Material
This menu enables the automatic operation of the
Material Identification function when the “STORE”
key is pressed. This menu also disables the
automatic operation of the Material Identification
function when the “STORE” key is pressed. When
the Material Identification function is enabled,
the operator is automatically prompted for the
identification of the Material that was just loaded.
When the Material Identification function is disabled,
you must enter the identification of the material
before you store the weight of the material.
Printer
This menu allows the selection of the brand of
printer. Currently, the only supported printers are
the Comtec and the Radix printers. However, any
standard ASCII printer with a serial interface will
work. Select the Radix printer in order to use
symbols when other languages are selected. The
printer must be connected to the Payload Control
System. The printer must be activated when the
printer menu is used. Use the “SCROLL” key in
order to locate the correct printer and press the
“STORE” key. The “STORE” key must be pressed
when the printer is used for the first time. The name
of the printer will be underlined if the printer is the
active choice.
Re-Zero “Re-Zero On / Re-Zero Off”
The function periodically reminds the operator to
“RE-ZERO”, when the function is activated. The
message advises the operator to “RE-ZERO”. If
the message appears at an inconvenient time, the
message can be cleared for two minutes. The
message will reappear again until the “RE-ZERO”
button is pressed by the operator.
When the machine first starts up the message
“RE-ZERO” will be frequently displayed. As the
machine warms up the message will appear less
frequently.
“RE-ZEROING” the bucket regularly, improves the
accuracy by compensating for changes associated
with pin lubrication, hydraulic oil temperature and
material carryback.
Velocity Check (0-10-65536)
The menu monitors the lift speed in the weigh
range. The number is set in terms of percent per
second times 10. When the lift speed exceeds the
value in the menu, an error will occur.
Setting the threshold to a high number will make
the PCS more tolerant to changes in the lift speed.
Setting the threshold to a low number will make
the PCS less tolerant to changes in the lift speed.
Changing the lift speed in the weigh range will
adversely affect the ability of the PCS to calculate
an accurate payload.
The default number used provides a good balance
between attaining good accuracy and allowing the
operator to achieve high productivity. The threshold
should be increased by small increments if the
operator is maintaining a constant lift speed and
is still receiving an excessive number of reweighs
associated with lift speed.
 13
Operation Section
System Setup Options

Note: If the threshold is set too high, the accuracy

can be decreased by allowing for operator
intervention during the weigh range. (Moving the
lift lever out of the detent position or changing the
engine speed.)

Start Of Lift (None / 5% / 10% / 15%)

The menu sets the amount of payload data that is
gathered before the bucket enters the weigh range.
The value is set as a percent of the full lift travel. The
value is relative to the bottom of the weigh range.

g00989880
Illustration 4
Sample Lift Range

Example – The lift range is set from 50% to 80%
and the “Start of Lift” is set to 10%. The PCS would
begin gathering data at the 40% point.
The default setting of 10% provides sufficient lead
data so that PCS can obtain an accurate reading
of the payload. Increasing this number to 15% will
provide slightly better accuracy. This will require
the operator to maintain a constant lift speed for a
larger part of the lift range. Decreasing this number
to 5% or “None” will reduce the lift range. This will
adversely affect the accuracy.
Setting this menu to a value of 1 will change one
digit on the display (30.2). Setting this menu to a
value of 2 will change two digits on the display
(30.23).
Skew Resolution (Low, Middle,
High, None)
The menu monitors the lift pressure during the
weigh range. If the pressure changes excessively
an error will occur.

Display Resolution (Auto, 1, 2)

The menu allows a convenient method for setting
the precision level in the Payload Control System.
The default setting for this function is “AUTO”.
14
Operation Section
System Setup Options
This feature will help the operator develop
good lifting techniques that will maintain loading
efficiency. This will allow the PCS to calculate
an accurate payload. Setting the menu value to
“Middle”, “High”, or “None” will increase the tolerant
of the PCS. This will compensate for the machine
and the operator induced noise.
The operator can have excessive reweigh notices
from the “SKEW” menu due to issues with the
machine. The lift capability of some machines is so
erratic that the “Low” threshold can not be used.
When these conditions occur the “Skew Resolution”
can be set to the “Middle” setting. If the PCS
is set to the “Middle” and the system continues
to flag excessive reweigh notices for the “Skew
Resolution”, then change the value to “High” but
check the following.
• The validity of the calibration
• Pin or pin lubrication (problems)
• Operator technique
• Valve and pump problems
Note: The “Skew” should only be set to “High” or
“None” if high accuracy is not an issue.
Temperature Compensation
(0-65536)
The option allows you to compensate for changes
in the temperature of the hydraulic oil. The default
setting for this function is 0 or OFF. The Temperature
Compensation requires some adjusting by the
service personnel.
Setting the Temperature Compensation
Note: Temperature compensation must be turned
on before the machine is calibrated. Start with the
number 12 for medium wheel loaders.
There are several methods that are used to
determine the optimum temperature compensation
coefficient.
Method A
Monitor the machine daily. Lower the number under
the following conditions.
• When the machine is cold the weight is too heavy.
• When the machine is hot the weight is too light.
Raise the number under the following conditions.
• When the machine is hot the weight is too heavy.
• When the machine is cold the weight is too light.
The optimum number will be found if the coefficient
is slowly adjusted over a period of a few weeks.
Method B
Use a clicker box in order to change the Electronic
Monitoring System to “Mode 2”. Display the
hydraulic oil temperature on the screen on gauge
3. Start the machine. Move the lift linkage but do
not warm up the hydraulic oil. Load several trucks.
Compare the weight of the PCS to the weight of
the scale. Record the hydraulic oil temperature.
The machine should be at the normal operating
temperature. Load several trucks. Record the
hydraulic oil temperature, weight of the scale and
weight of the PCS. Calculate the error of the PCS
by subtracting the weight of the PCS from the
weight of the scale. Calculate the average error
by adding the errors and dividing by the number
of truck loads. Calculate the average temperature
by adding the hydraulic oil temperature for each
lift and dividing by the number of truck loads. The
optimum coefficient can then be calculated with the
following formula.
Illustration 5
g00988693
Password
This allows you to change the password. This will
replace the default password. This password is also
used in order to limit access to the calibration mode.
Note: Make sure that you record your new
password. This password will be needed for
future calibrations and future changes. If the new
password is lost, contact your Caterpillar dealer.

i01901180
System Calibration
SMCS Code: 7494
This mode allows the calibration of the sensor for
the lift arm. This mode allows the calibration of
the weigh system. This mode is protected by the
password of the owner. Pressing the “CAL” key
will display the number of calibrations that have
been performed. The date of the last calibration will
then be displayed. The system will then request
the password of the owner. To enter the calibration
mode, enter the password of the owner. The default
password is 12345. This was set at the factory.
Press “STORE”. Pressing the “SCROLL” key will
display the previous calibrations. Continue to press
the “scroll” key in order to view earlier calibrations.
When the word “End” is displayed, there are no
more previous calibrations.
Note: See Service Manual, SENR6614, “Payload
Control System (PCS)” for more information on the
complete calibration procedure.
If the zero function is used to compensate for
changes then calibration should be performed
whenever the average ambient air temperature
changes 10 C (50 F).
Note: The following service procedures will require
recalibration of the system.
(1) Replacement of a Pressure Sensor
(2) Adjusting the position sensor or replacing the
position sensor
(3) Replacement of the display unit
(4) Replacing the components of the bucket or
replacing the components of the bucket control
linkage
(5) Recalibration should also be performed if the
PCS is moved from one machine to another
machine.
(6) The software for the Payload Control System
is updated.
15
Operation Section
System Setup Options
Calibration Steps
Preliminary Procedures
The following steps briefly describe the calibration
procedure. A more detailed description is included
in the service manual. See Service Manual,
SENR6614, “Payload Control System (PCS)” for
more information. The steps that are used for
calibration will be shown on the display of the
payload control system. For all calibration, the
bucket must be in the fully tilted back position.
Warm up the machine. Ensure that the kickouts are
set for the maximum height.
Note: Set the display for the weights before you
start the calibration. The display for the weights can
be ENGLISH or metric.
Note: The kickout should be adjusted in order to
ensure that weighing is completed prior to the start
of kickout.
Note: The 988G has an automatic tilt feature. This
tilts the bucket forward slightly at the top of the lift
range. This feature can interfere with the calibration.
Use the following procedure in order to place
the bucket in the proper position for calibration
on the 988G only. This procedure can be used
for a full bucket or for an empty bucket. These
instructions are not for setting the zero offset. For all
other machines, proceed directly to the calibration
procedure.
1. Lower the bucket to ground level. Fully rack
back the bucket.
2. Lift the bucket to the maximum height. Hold the
lift lever for approximately five to ten seconds.
This will allow the automatic tilt feature to tilt the
bucket forward slightly to the desired position.
3. Lower the bucket to the ground without changing
the position of the bucket. The bucket is now
in the correct position for calibration. Do not
change the tilt position of the bucket for the
remainder of the calibration. You may now
proceed with calibration.
Calibration Procedure
1. CALIBRATE THE LIFT ARM POSITION SENSOR.
This is the first step in the calibration. Place
the bucket on the ground. Fully rack back the
bucket. Press the “STORE” button. Then raise
the bucket to the highest possible position of the
lift arm and then press “STORE”. Acceptable
ranges for the lift arms at the lowest position are
from 6500 to 22000. Acceptable values with the
lift arm at the highest position are from 44500
to 61600.
16
Operation Section
System Setup Options
2. CALIBRATE AN EMPTY BUCKET. During this
step, the operator will be instructed to lift an
empty bucket. The bucket should be fully racked
back. The operator should lift the bucket at
normal lifting speed. If the two lifts match closely,
then the calibration will proceed to the next step.
If the two lifts do not match, the operator will
be instructed to lift another bucket. This will be
repeated until two lifts match. The bucket should
be lifted with the lift control in the detent position.
The lift control should be moved smoothly into
the detent position.
Note: Calibration should be done at normal
operating speed.
3. CALIBRATE A FULL BUCKET. During this step,
the operator will be instructed to lift a full bucket.
Use a known weight or use a full bucket of
material. The bucket should be fully racked back.
The operator should lift the bucket at normal
lifting speed. If the two lifts match closely, then
the calibration will proceed to the next step.
If the two lifts do not match, the operator will
be instructed to lift another bucket. This will be
repeated until two lifts match. The bucket should
be lifted with the lift control in the detent position.
The lift control should be moved smoothly into
the detent position.
Note: Calibration should be done at normal
operating speed.
Note: Do not lose any loose material prior to
determining the weight.
4. CALIBRATE THE EMPTY BUCKET STATIONARY.
Lower the lift arm below the start weigh point.
Then, raise the lift arm slowly. The distance to
the next stationary position will be shown on
the bottom line of the display. When this value
reaches zero, the top line of the display will
instruct the operator to STOP. The lift arms must
be held stationary until the system instructs
the operator to raise the bucket into the next
calibration point. Ten calibration points will be
taken in the weigh range.
5. CALIBRATE THE FULL BUCKET STATIONARY.
Load the bucket. Use a known weight or use a
full bucket of material. The steps are identical to
the steps that are used for calibrating an empty
bucket.
Note: It is very important to calibrate the system with
a load that is very close to the rated load. Do not
use a load that is too small. The operator will receive
the message “MAX” during the weighing process, if
a larger load is used. If the message “MAX” appears
during the weighing process, dump some material
from the bucket and try again. If the message
“MAX” repeatedly appears, recalibration is required.
See Operation Manual, “System Calibration”.
Note: Do not lose any loose material prior to
determining the weight.
6. USE VELOCITY COMPENSATION IN ORDER
TO CALIBRATE A FULL BUCKET. This step
requires the operator to lift the bucket eight times
at engine rpm from 1000 to 2400. This is for
software package 2.09 and 2.09R. Maintain the
required engine rpm as close as possible. If the
machine cannot attain the final engine speed
that is requested, run at High Idle for this step.
The lift lever should be smoothly moved from
neutral to the detent position.
Note: If the message “LIFT SLOWER” appears
after lifting the bucket eight times, lift the bucket
at 1000 rpm. If the “LIFT SLOWER” message is
still displayed, lift the bucket at 900 rpm, until the
message “GOOD LIFT” comes on the screen.
7. ENTER THE WEIGHT OF THE FULL BUCKET
. Enter the weight of the material that is in the
bucket. The system will wait at this point while
the weight in the bucket is determined. The
electrical system should not be shut off prior
to entering the actual weight or the calibration
information will be lost.
8. ZERO THE EMPTY BUCKET. Empty the bucket.
Tilt back the bucket. The operator should lift the
bucket at normal lifting speed. Press the “ZERO”
key. This completes the calibration.
9. DETERMINE THE WEIGH RANGE. See Operation
Manual, “Owner Setup Functions” for information
on setting the Weigh Range.

System Operation
i01900812
Normal Weighing Mode
SMCS Code: 7494
This is the default mode of the system. In this
mode, the top line displays the last bucket weight
in the selected units. The bottom line displays the
accumulated “TRUCK” weight. If the PCS is in
the “TARGET” mode, the weight needed to hit the
desired target weight of the truck.
The new bucket weights are added to the truck
total by simply lifting the bucket through the weigh
range in a uniform manner with the lift lever in the
full detent position.
Machine Considerations
DUE TO THE SIGNIFICANT VARIATION IN THE
VISCOSITY OF HYDRAULIC OIL, THE MACHINE
HYDRAULICS SYSTEM SHOULD BE AT THE
NORMAL OPERATING TEMPERATURE BEFORE
THE BEGINNING OF WEIGHING OPERATIONS.
In order for the Payload Control System to provide
accurate, reliable weights, your machine must be
kept in good working order. Low hydraulic levels or
poorly lubricated linkage pins will adversely affect
the weighing accuracy of the system.
Lifting Techniques and
Considerations
The operator should pay attention to the following
details during the lifting sequence. This can
significantly improve the overall weighing accuracy.
1. If the machine has been idle for more than 15
minutes, you should exercise the lift linkage
several times in order to lubricate the pins.
The Payload Control System compensates for
the changes in hydraulic oil temperature. The
PCS does not compensate for the linkage
that becomes stiff due to the lack of machine
movement. The operator should perform ten
empty lifts, by raising the bucket to full height
from the ground. This will exercise the pins and
the lift arms. This action will cycle the hydraulic
oil through the system.
2. Fully rack back the bucket before weighing.
17
Operation Section
System Operation
3. Weighing should be performed on a flat surface.
Weighing material with the machine on a slope
will affect accuracy by changing the center of
gravity of the load.
4. Maintain a constant engine speed throughout
the weigh range. Changing the lift speed in the
weigh range will affect the compensation of the
lift speed.
5. Start the lift at the lowest available starting point.
6. Move the lift lever smoothly into the detent
position.
7. The lift lever should be in the full detent position
through the weigh range.
8. Move the kickout of the lift height well beyond
the end of the weigh range.
9. When you load the truck watch for loss of
material.
10. Set the machine’s ride control to AUTO or OFF if
the machine is equipped with ride control.
11. Enable the “Re-Zero” function in the owner setup
functions.
12. Comply with the request for a “Re-Weigh” by
the PCS.
13. Use consistent loads when multipass loading
is used to load trucks.
14. Keep the values of the lift (Velocity and Skew
Resolution) set as tight as possible. Keep the
start of the lift at 10% or 15%.
15. The highest accuracy can be achieved when
the machine is stationary.
16. Configure the machine for a wide weigh range.
A 30% weigh range (50% to 80%) is preferable.
17. Calibrate the machine at the same lift speed of
the operator.
18. The machine should be fully warmed up before
you attempt a calibration.
19. A sudden movement of the machine will
adversely affect the accuracy of weighing. You
perform a directional shift during weighing.
20. Easing the lift lever from the center position to
the full detent position gradually can decrease
the oscillations in the hydraulic system. This will
decrease vibration, thus improving weighing
accuracy and repeatability.
18
Operation Section
System Operation

21. An uneven working area will affect weighing

accuracy.

22. The weigh range should be set to the smoothest

operating portion of the lifting cycle. See
Operator Manual, “Owner Setup Functions” for
more information.

Error and Warning Messages

Table 1
Error and Warning Messages
Payload Control System (Message) Cause
“LOWER” The position of the bucket is too high in
order to start the weighing.
“RE-DO” Lift speed was too slow.
“REW-1” The lift paused in the weigh range.
“REW-2” Machine movement or bounce causes
excessive pressure spikes.
“REW-3” Lift speed changed too much during the
lift.
“REW-4” Lift was too slow.
“Lift Bucket 10 Times” The machine has been idle for more
than 4 hours.
“RE-ZERO PCS” This is an automatic reminder to
“RE-Zero”. This will reduce errors that
are caused by pressure changes.
Correction
Lower the bucket until the “LOWER”
message disappears.
Repeat the lift with increased engine
speed.
Repeat the lift and maintain constant
engine speed throughout the lift. Ensure
that the lift kickout is set above the end
of the weigh range.
Repeat the lift. Use the following steps:
1. Lower the start of the lift position
closer to the ground.
2. Hold the machine at a constant
engine RPM through the entire weigh
range.
3. Lift with a lower engine RPM
4. Lift with the lift lever in the DETENT
position
5. Ensure that the machine is not
moving at excessive speeds or over
rough ground.
6. Perform the lift while the machine is
in a stationary position. Perform the lift
with minimal motion of the machine.
Repeat the lift with a more constant
engine speed.
Repeat the lift with increased engine
RPM.
Exercise the front linkage and warm
up the hydraulic oil by performing a
minimum of 10 lifts.
1. Lower the bucket to the ground.
2. Fully rack back the empty bucket to
the stops.
3. Raise the engine speed to the typical
lifting speed.
4. Gently pull the lift lever into the detent
position.
5. Maintain a constant engine speed
throughout the entire lift.
6. When the weight has been displayed,
press the “ZERO” button on the display.

“Lower”
This message will appear on the screen if the
bucket is stopped in the weight range. The operator
should lower the bucket efficiently so that an
accurate weight can be achieved. The Payload
Control System will not calculate a weight while the
“LOWER” message is displayed on the screen.
“RE-DO”
This message will appear when the lift speed is too
slow. The message only appears when an abnormal
lifting condition has occurred.
Note: The operator should lower the bucket to a
point below the start of the lift range. The operator
should repeat the lift.
“REW-1”
This message appears if the bucket stops moving
during the “Start of Lift Range” or during “Weigh
Range”. The message appears when the operator
does not place the lift lever in the full DETENT
position. The operator releases the lift lever before
the bucket has travelled completely through the
weigh range.
In order to correct the error, lower the bucket to
the ground. Perform a smooth lift. In order for the
operator to achieve a smooth lift, the lift lever
must be in the detent position and the engine at
a constant speed.
Note: Press the “REWEIGH” button that is located
above the number 2 on the keypad before you
perform a “REWEIGH”. The button is marked
“REW”. If you do not press the button the PCS will
count the lift twice.
“REW-2”
This message appears when the motion of the
machine or bounce causes pressure spikes. This
will affect the accuracy of the payload. The “SKEW”
identifies excessive noisy lifts. The function then
flags the lifts as potential problems. Refer to the
Owner Setup Functions for additional information
on the “SKEW” function.
In order to correct the error, lower the bucket to
the ground. Perform a smooth lift. In order for the
operator to achieve a smooth lift, the lift lever
must be in the detent position and the engine at
a constant speed.
19
Operation Section
System Operation
Note: Press the “REWEIGH” button that is located
above the number 2 on the keypad before you
perform a “REWEIGH”. The button is marked
“REW”. If you do not press the button the PCS will
count the lift twice.
“REW-3”
This message appears when the lift speed has
changed by more than the threshold of the lift
speed. This error occurs because the operator
lowers the engine speed during the lift. The “REW-2”
and “REW-3” features monitor most errors that
occur during the lift range.
In order to correct this error, lower the bucket and
then perform a smooth lift. In order for the operator
to achieve a smooth lift, the lift lever must be in the
detent position and the engine at a constant speed.
Note: Press the “REWEIGH” button that is located
above the number 2 on the keypad before you
perform a “REWEIGH”. The button is marked
“REW”. If you do not press the button the PCS will
count the lift twice.
“REW-4”
The message appears when the travel time through
the weigh range is too long. The limit of the PCS
is no more than six seconds for the bucket to
travel through the weigh range. This error remains
in the software for special situations and for
troubleshooting purposes.
In order to correct this error, lower the bucket and
then perform a smooth lift. In order for the operator
to achieve a smooth lift, the lift lever must be in the
detent position and the engine at a constant speed.
Note: Press the “REWEIGH” button that is located
above the number 2 on the keypad before you
perform a “REWEIGH”. The button is marked
“REW”. If you do not press the button the PCS will
count the lift twice.
“Lift Bucket 10 Times”
This message will appear when the following
scenario occurs.
• The lift system has been idle for more than 4
hours.
• For the first time, the bucket enters the “Start of
Lift” or “Weigh Range”.
This message reminds the operator to exercise the
linkage after the linkage has been idle.
20
Operation Section
System Operation

The operator should cycle ten full buckets of i01901510

material. Lift the buckets to the kickout. Dump the
buckets. Then return to the normal weigh mode. Keypad Modes and Functions
This is the best way to distribute grease across the
pins of the linkage and the hydraulic oil through SMCS Code: 7494
the system. The second option involves lifting a
full bucket of material ten times. The third option The Payload Control System has many functions.
involves lifting ten empty buckets from the ground to These functions are accessed through the keypad.
the KICKOUT position. The final option is pressing Many of the keys have a dual purpose of entering
the “CLEAR” button on the keypad. Then return to numbers and selecting a specific function. These
the normal weigh mode. keys can select a specific function when the
Payload Control System is in the NORMAL weigh
Note: The Payload Control System will provide mode or in the STANDBY mode. The NORMAL
the best results when the hydraulic oil is properly weigh mode shows the weight of the bucket and
circulated through the system and the pins are the truck weight. The STANDBY mode shows the
properly lubricated. time and the date. The Cat symbol is lighted in
both of these modes. All other modes remove this
symbol from the display.
“Re-Zero” (Payload Control System)
This reminds the operator to use the “Re-Zero”
function. Performing this function reduces the
errors that are caused by pressure changes. This
message can be cleared if the operator is in the
middle of loading trucks but the message will return
in two minutes. The message can be cleared many
times by the operator.

Note: Press the “CLEAR” button in order to store

the message.

Use the following steps in order to “Re-Zero”.

1. Lower the bucket to the ground. Fully rack back

the bucket.

2. Raise the engine speed to the typical lifting

speed.

3. Gently pull the lift lever into the detent position.

4. Maintain a constant engine speed throughout

the entire lift.

5. When the weight has been displayed, press the

“ZERO” button on the display.

Note: Performing the “Re-Zero” function on the

machine takes 6 to 8 seconds. This function is
important to achieving high accuracy.

g00450544
Illustration 6

Reweigh Mode
The “REWEIGH” mode is entered by pressing the
“REW” key. The “REWEIGH” mode is also entered
by pressing the optional “REWEIGH” button. The
operator must enter the “REWEIGH” mode before
the operator can reweigh the bucket or PCS will
count the lift twice. The top line of the display will
show the message “REWEIGH”. The payload control
system will replace the previous bucket weight with
a new bucket weight while the system is in this
mode. The system will replace the previous weight
of the truck with a new total of the truck.
You may lift the bucket again. The preferred method
is lower the bucket below the “Start to Lift” point.
Then press the “REW” key in order to enter the
“REWEIGH” mode. Place the lift control lever into
the detent position in order to lift the bucket. Use a
constant engine speed. Perform a smooth lift.
If a stationary position is used, the stationary
position must be above the begin weigh point. The
payload control system will return to the NORMAL
weigh mode when the new weight has been taken.
Note: Lifting the bucket again is recommended
after pressing the “REW” key. The reweigh mode is
more accurate than the stationary reweigh mode.
All weighing must be done with a fully tilted back
bucket.
The reweigh mode can be aborted by pressing
the “CLEAR” key, the “REW” key, or the optional
“Reweigh” button.
Standby Mode
The standby mode is entered by pressing the
“STBY” key. In this mode, the payload control
system shows the date and time. Weights will not
be measured in this mode.
Press the “CLEAR” key in order to resume the
normal weigh mode. Pressing any other function
key will execute that function.
Note: The “STBY” key can be used when the
operator wishes to move to a different dump
location. The total weight will not be changed.
21
Operation Section
System Operation
Excess Mode
The Excess mode is entered by pressing the “EXC”
key or the optional Excess button. The operator
must enter the “EXCESS” mode before performing
excess weighing. The top line of the display will
show the message “EXCES”. In this mode, a partial
bucket can be dumped into the truck. Tilt back the
bucket and then press the “EXC” key. The current
weight of the bucket will be subtracted from the
previous weight of the bucket. A new total of the
truck will be shown.
This function can be repeated again. Dump some
additional material, and then repeat the excess
function. All excess weighing must be done with a
fully tilted back bucket.
You may lift the bucket again. The preferred method
is lower the bucket below the “Start to Lift” point.
Then press the “EXC” key in order to enter the
“EXCESS” mode. Place the lift control lever into the
detent position in order to lift the bucket. Use a
constant engine speed. Perform a smooth lift.
The payload control system will return to the normal
weigh mode when the weight of the bucket has
been subtracted from the weight of the truck.
The Excess mode can be aborted by pressing the
“CLEAR” key, the “EXC” key, or the optional Excess
button.
Zero Function
The zero function is used in order to adjust for
changing weight of the bucket. As the bucket
begins to wear, the empty weight of the bucket will
become a negative value.
Warm the machine to normal operating temperature.
Weigh an empty tilted back bucket. The engine
speed should be 2000 rpm. Press the “ZERO” key
within thirty seconds. The weight of the bucket
should be within 8% of the full weight of calibration
. The new zero will be accepted. The message
“ZERO ACCEPTED” will be displayed on the top
line if the new zero offset is accepted.
Immediately weigh the empty bucket. The display
should read zero.
The message “WEIGH EMPTY, PRESS ZERO” will
be shown if the current empty weight of the bucket
was taken prior to thirty seconds. If the weight is
too large, the message “TOO HEAVY FOR ZERO”
will appear and the payload control system must
be recalibrated.
22
Operation Section
System Operation
Identification of the Truck
A five digit number is used for identification of the
truck. (0 to 99999).
This mode is entered by pressing the “TRK” key
while you are in the normal mode. The current truck
will be displayed on the bottom line. A new truck can
be selected by entering a numerical identification
number. Press the “STORE” key in order to save the
new identification number of the truck. This mode
can be aborted by pressing the “CLEAR” key.
Identification of the Material
This mode is entered by pressing the “MAT” key
while you are in the normal mode. The currently
selected material will be displayed on the top line.
The index number of the material is displayed on
the bottom line.
A new material can be selected by using one of
two methods.
(1) Enter the new number of the material. If you
have software package 2.04,2.05, or 2.06, you
can enter 0 through 20. If you have software
package 2.07 you can enter 0 through 99.
You can also press the “SCROLL” key until
the desired material is displayed. Press the
“STORE” key.
(2) This mode will automatically abort after several
seconds if no keys have been pressed. This
mode may also be aborted by pressing the
“CLEAR” key.
Target Weight of the Truck
This mode is entered by pressing the “TRGT” key
while you are in the normal mode. In this mode, the
message “TRGT” will be displayed on the top line
and the current target weight will be displayed on
the bottom line.
A new target weight can be entered by entering the
appropriate digits and pressing the “STORE” key.
Enter zero by using the “BRT / 0 ” key. Press the
“STORE” key. This will reset the payload control
system to normal weigh mode.
This mode will automatically abort after several
seconds if no keys are pressed. The mode may be
aborted by pressing the “CLEAR” key.
Total Mode
The total mode is entered by pressing the “TOT”
key in the normal mode. In this mode, the message
“TOTAL” is displayed on the top line. The total
weight of all of the materials that have been loaded
since the previous total is shown.
To reset the total, enter 0 by using the “BRT / 0 ”
key. Press the “STORE” key. This will reset the totals.
Press the “PRNT” key while the total is displayed.
All of the loads of the trucks that are included in the
total will be printed. The total mode can store data
for approximately 2500 trucks.
This mode will automatically abort after several
seconds if no keys are pressed. This mode may
also be aborted by pressing the “CLEAR” key.
Total of the Materials
The mode for total material is entered by pressing
the “MOT” key when you are in the normal mode.
In this mode, the material will be displayed on the
top line. The total for that material is displayed on
the bottom line. If no keys are pressed, all of the
materials will be displayed for several seconds. The
normal mode will be resumed.
Enter the number 0 by using the “BRT / 0 ” key.
Press the “STORE” key while you are in the Total
mode. This will reset the total of materials.
Press the “SCROLL” key. This will stop the automatic
scrolling. The system will not abort automatically.
You can then press the “SCROLL” key. This will
allow you to view each total. Press one of the
other numbered keys. This will stop the automatic
scrolling on the current material.
Press the “PRNT” key while the total of material is
displayed. This will print all of the loads of the trucks
that are included in that total.
This mode will automatically abort after several
seconds if no keys are pressed. This mode may
also be aborted by pressing the “CLEAR” key.
Printing Tickets
Press the “PRNT” key after a truck has been loaded.
This will print single truck tickets. The previous truck
tickets may be printed at any time until the “STORE”
key is pressed for the next truck. Multiple tickets
may be printed by pressing the “PRNT” key more
than one time.

Brightness
The display fades at night. You can adjust the
brightness to your preference by pressing the “BRT”
key. You must be in the normal mode or in the
standby mode. The brightness will cycle through
seven levels of brightness.
Note: If you cannot read the display during sunlight,
press the “BRT” key several times.
Service Mode
To enter the service mode, press the “SERV” key
while you are in the normal mode. The service mode
is automatically entered on powerup if the unit is not
calibrated or other faults are present.
Display Faults
This mode is used to view any logged faults. If there
are no faults, the top line will display “NO FAULTS”.
The mode will automatically advance to the Position
Sensor display.
If there are faults, a message will be displayed
on the top line. The CID:FMI message will be
displayed on the bottom line. This information will
be alternated with the count for that fault.
If the fault is currently active then the “SERV CODE”
symbol will be illuminated.
If the currently displayed fault is NOT active,
pressing the “CLEAR” key will remove the fault from
the log. If the fault is active, pressing the “CLEAR”
key will advance to the next fault in the same
manner as the “SCROLL” key. Press the “CLEAR”
key while the “END” message is displayed. You will
return to the normal mode.
Pressing the “SCROLL” key will view other faults in
the same log.
Press the “SERV” key in order to exit this mode.
Press the “NEXT FNCT” key in order to advance to
the Position Sensor display mode.
Display for the Position Sensor
The units for the position sensor will be displayed
on the bottom line. The number may be from 2000
to 63000. Acceptable values with the lift arm at
the highest position are from 44500 to 61600.
Acceptable values with the lift arm at the lowest
position are from 6500 to 22000.
To end this mode, press the “CLEAR” key.
23
Operation Section
System Operation
To advance to the display mode for the Pressure
Sensor, press the “NEXT FNCT” key.
Display for the Pressure Sensor (Head
End)
The current cylinder pressure is displayed in tenths
of a PSI.
To end this mode, press the “CLEAR” key.
Pressing the “NEXT FNCT” key will return to the
display for the Position Sensor.
Machines that are equipped with a pressure sensor
on the rod end of the cylinder will show the current
pressure in the rod end in tenths of a PSI.
i00882887
Payload Control System/PC
Off-Board System
SMCS Code: 7494
The Payload Control System (PCS) currently stores
truck load cycle data that can be transferred to
a personal computer (PC) for data analysis. The
system also provides the ability to modify the
material descriptions and ticket header information.
The information can be transferred from the
machine through a process called downloading.
Downloading is done with a laptop computer
(100% IBM compatible) using Caterpillar software
packageJERD2161, and a connecting cable
127-9797. The laptop computer will connect
with the system using the connecting cable
127-9797 with the M-S connector located in the
operators compartment in the cab of wheel loaders.
Approximately 2500 truck loads can be stored in
the control.
Note: For more information on the PCS/PC system,
refer to User Manual, JEBD3006.
At start up the display may scroll a warning
message “TRUCK DATA MEMORY **% FULL”,
where ** is 90, 98, and 100% full. The 100%
full warning will be repeated two times and then
the warning will be disabled until the data is
downloaded to the PC. This warning will also appear
when a load is stored which causes the percent to
transition from 89 to 90 etc. If the on-board memory
is full the latest data will continue to be stored. The
oldest truck data will be lost.
Note: This warning cannot be disabled and will go
away.
24
Operation Section
System Operation

g00450803
Illustration 7
Character Table

The Payload Control System (PCS) will automatically

select the correct language character set if the
RADIX printer option is selected. The previous
special character table should be used in order to
translate from the old US character set used on the
PCS/PC to the desired language character.
 25
Reference Information Section
Reference Materials

Reference Information
Section

Reference Materials
i00903737

Caterpillar Reference Material

SMCS Code: 7494

The following literature can be obtained from any

Caterpillar dealer.

• Service Manual, SENR6614, “Payload Control

System (PCS)”

i00883706

Additional Reference Material

SMCS Code: 7494

SAE J754, “Nomenclature” This can normally be

found in the SAE handbook.

SAE J183, “Classification” This can normally be

found in the SAE handbook.

i01901617

Warranty Information
SMCS Code: 7494

Consult your Caterpillar dealer in order to obtain

warranty information.

May not be legal for trade. Consult your local

regulations.
26
Index Section
Index
A N
Additional Reference Material ............................... 25
C Machine Considerations ....................................
Caterpillar Reference Material............................... 25
F Operation Section.................................................... 6
Foreword..................................................................
California Proposition 65 Warning .......................
Caterpillar Product Identification Number ............
Certified Engine Maintenance..............................
Literature Information...........................................
Machine Capacity ................................................
Maintenance ........................................................
Operation .............................................................
Safety...................................................................
G Setting the Weigh Range ................................... 11
General Information.................................................
Getting Started.....................................................
Introduction ..........................................................
General Keypad Operations ....................................
Clear Key .............................................................
Menu Basics ........................................................
Next Function Key................................................
“Scroll” Key...........................................................
“Store” Key ...........................................................
I
Important Safety Information ................................... 2
K
Keypad Modes and Functions ............................... 20
Brightness.......................................................... 23
Excess Mode ..................................................... 21
Identification of the Material............................... 22
Identification of the Truck ................................... 22
Printing Tickets .................................................. 22
Reweigh Mode ................................................... 21
Service Mode..................................................... 23
Standby Mode.................................................... 21
Target Weight of the Truck ................................. 22
Total Mode ......................................................... 22
Total of the Materials.......................................... 22
Zero Function..................................................... 21
Normal Weighing Mode ......................................... 17
Error and Warning Messages ............................ 18
Lifting Techniques and Considerations .............. 17
17
O
Operator Setup Functions ....................................... 8
5 Setup for the Operator ...................................... 10
4 Owner Setup Functions ......................................... 10
5 AUTO Truck ID ................................................... 12
4 Automatic Identification of the Material ............. 12
4 Display Resolution (Auto, 1, 2)........................... 13
5 Machine Identification ........................................ 12
4 Operator ID ........................................................ 12
4 Password ..................................................... 10, 14
4 Printer ................................................................ 12
Re-Zero “Re-Zero On / Re-Zero Off” ................. 12
Setting the Time and the Date ........................... 10
Skew Resolution (Low, Middle, High, None) ...... 13
6 Start Of Lift (None / 5% / 10% / 15%) ................ 13
6 Temperature Compensation (0-65536) .............. 14
6 Tickets Menu...................................................... 12
7 Velocity Check (0-10-65536).............................. 12
7
7
7 P
7
7 Payload Control System Features ........................... 6
Payload Control System/PC Off-Board System..... 23
R
Reference Information Section .............................. 25
Reference Materials .............................................. 25
S
System Calibration ................................................ 15
Calibration Steps................................................ 15
System Operation.................................................. 17
System Setup Options............................................. 8
T
Table of Contents..................................................... 3
 27
Index Section

Warranty Information ............................................. 25

Weighing Material.................................................... 6
28
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the
Operation and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
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