Service Manual: Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058-2033 (973) 377-9000

SERVICE MANUAL
Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058-2033 (973) 377-9000
SERVICE MANUAL
Pioneer™ Balances
The information contained in this manual is believed to be accurate at the time of publication, but Ohaus
Corporation assumes no liability arising from the use or misuse of this material. Reproduction of this
material is strictly prohibited.
Material in this manual is subject to change.
© Copyright 2008 Ohaus Corporation, all rights reserved.

TM Registered trademark of Ohaus Corporation.
TABLE OF CONTENTS
Page No.
CHAPTER 1 GETTING STARTED
1.1 Introduction ................................................................................................................1-1
1.2 Service Facilities........................................................................................................1-1
1.3 Tools and Test Equipment Required .........................................................................1-2
1.3.1 Special Tools ......................................................................................................1-2
1.3.2 Standard Tools and Test Equipment ..................................................................1-2
1.4 Specifications.............................................................................................................1-2
1.5 Balance Operation .....................................................................................................1-5
1.5.1 Overview of the Controls ....................................................................................1-5
1.5.2 Overview of the Display Indicators .....................................................................1-6
1.5.3 Power On ...........................................................................................................1-7
1.5.4 Power Off ...........................................................................................................1-7
1.5.5 Menu Setup ........................................................................................................1-7
1.5.6 Menu Structure ...................................................................................................1-7
1.5.7 The Load Cell .....................................................................................................1-8
1.6 Connecting the RS232 Interface................................................................................1-9
1.7 RS232 Commands ..................................................................................................1-10
CHAPTER 2 TROUBLESHOOTING
2.1 Troubleshooting .........................................................................................................2-1
2.1.1 General Procedures for Troubleshooting ...........................................................2-1
2.2 Diagnostic Guide .......................................................................................................2-1
2.2.1 Diagnosis............................................................................................................2-1
2.3 Error Codes ...............................................................................................................2-4
CHAPTER 3 MAINTENANCE PROCEDURES

3.1 Preventive Maintenance ............................................................................................3-1
3.1.1 Preventive Maintenance Checklist .....................................................................3-1
3.2 Opening the Balance .................................................................................................3-1
3.2.1 Variations in Opening Pioneer Models ...............................................................3-2
3.3 Load Cell Removal and Disassembly ........................................................................3-3
3.3.1 Variations in Pioneer Load Cells ........................................................................3-3
3.3.2 Disassembly of Precision Balances with Internal Calibration .............................3-4
3.3.3 Removing Internal Calibration Weights ..............................................................3-5
3.3.4 Servicing the Internal Calibration Mechanism ....................................................3-5
3.3.5 Reassembling the Internal Calibration Mechanism ............................................3-6
3.3.6 Disassembly of Precision Balances with InCal Mechanism ...............................3-6
3.3.7 Removing the Load Cell – Precision Balances...................................................3-7
3.3.8 Load Cell Disassembly – Precision Balances ....................................................3-8
3.3.9 Position Sensor Board Removal/Replacement/Adjustment – Precision...........3-13
3.3.10 Main Printed Circuit Board (PCB) Replacement – All Balances.......................3-14
3.3.11 Load Cell Reassembly – Precision Balances ...................................................3-15
3.3.12 Removing the InCal Mechanism from InCal Analytical Balances.....................3-19
3.3.13 Removing Internal Calibration Weights and Components................................3-19
3.3.14 Re-Installing Internal Calibration Components .................................................3-21
3.3.15 Load Cell Removal/Installation – Analytical Balances......................................3-21
3.3.16 Disassembling Analytical Load Cells................................................................3-22
3.3.17 Position Sensor PC Board Removal/Replacement/Adjustment - Analytical.....3-28
3.3.18 Reassembling Analytical Load Cells ................................................................3-29
3.3.19 Block Style Load Cell Removal & Replacement...............................................3-34
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3.3.20 Block Style Load Cell Disassembly & Replacement with Load Cell Kit............3-35
3.3.21 Progressive Disassembly of Block Style Load Cells ........................................3-35
3.3.22 Internal Calibration Testing ..............................................................................3-36
3.3.23 InCal Motor Removal & Replacement ..............................................................3-36
3.3.24 InCal Mechanism Removal...............................................................................3-37
3.3.25 InCal Mechanism Installation ...........................................................................3-38
3.3.26 Position Sensor Assembly Removal/Installation on MFR Load Cell ................3-39
3.3.27 Removing the Block Style Load Cell from the Base Plate................................3-40
3.3.28 Installing the Block Style Load Cell on the Base Plate .....................................3-41
3.3.29 Removal and Installation of the Block Style Load Cell PC Board.....................3-42
3.3.30 Removing the Ratio Beam on Block Style Load Cells......................................3-43
3.3.31 Installing the Ratio Beam on Block Style Load Cells........................................3-47
3.3.32 Installing the InCal Weight Arm ........................................................................3-49
3.3.33 Installing the Load Cell PCB-Temperature Sensor-Position Sensor ................3-51
3.2.34 Setting the Up/Down Stop Screw on Block Style Load Cells ...........................3-53
CHAPTER 4 TESTING
4.1. Testing .......................................................................................................................4-1
4.1.1 Test Masses Required .......................................................................................4-2
4.2 Operational Test ........................................................................................................4-1
4.3 Segment Display Test................................................................................................4-1
4.4. Performance Tests ....................................................................................................4-2
4.4.1 Precision Test.....................................................................................................4-2
4.4.2 Off-Center Load Test..........................................................................................4-3
4.4.3 Off-Center Load Adjustment for Precision Models .............................................4-4
4.4.4 Off-Center Load Adjustment for Analytical Models.............................................4-5
4.4.5 Off-Center Load Adjustment for Block Style Models ..........................................4-6
4.4.6 Repeatability Test...............................................................................................4-7
4.4.7 Linearity Test......................................................................................................4-9
CHAPTER 5 DRAWINGS AND PARTS LISTS

5-1 Precision Top Load Balance Housing & Internal Parts..............................................5-2
5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts..............................5-4
5-3 Square Pan Block Style Square Pan Balance: Housing & Internal Parts ..................5-6
5.4 Precision Draft Shield Balance with Draft Shield: Housing & Parts ...........................5-8
5.5 Analytical Balance: Housing & Internal Parts ..........................................................5-10
5.6 Precision Balance Load Cell & Parts .......................................................................5-12
5.7 Analytical Balance Load Cell & Parts ......................................................................5-14
5.8 Block Style InCal Load Cell & Parts.........................................................................5-26
Appendix A STANDARD CALIBRATION

A.1 Calibration................................................................................................................. A-1
A.1.1 Calibration Masses ............................................................................................ A-1
A.2 Span Calibration ....................................................................................................... A-1
A.3 Linearity Calibration .................................................................................................. A-2
Appendix B SERVICE CALIBRATION

B.1 Entering the Service Menu ....................................................................................... B-1
B.2 Ramp ........................................................................................................................ B-1
B.3 Service Span Calibration .......................................................................................... B-2
B.4 Service Linear Calibration......................................................................................... B-3
Pioneer™ Balances Service Manual ii Ohaus Corporation www.ohaus.com

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Page No.
APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS
C.1 Restore EEPROM Data ............................................................................................ C-2
C.2 Replace Load Cell .................................................................................................... C-3
C.3 Install new Main Printed Circuit Board...................................................................... C-4
C.4 Update Software in the Balance ............................................................................... C-5
C.5 Diagnostics ............................................................................................................... C-6
C.5.1 Incal Weight Mechanism Testing ......................................................................... C-6
LIST OF TABLES
TABLE NO. TITLE Page No.
1-1 Specifications: External Calibration Models (includes M Models) .........................1-2
1-2 Specifications: Internal Calibration Models (C & CM) ...........................................1-3
1-3 Specifications: Carat Models.................................................................................1-3
1-4 Specifications: Gold Models (External Calibration) ...............................................1-4
1-5 Specifications: Gold Models (Internal Calibration) ................................................1-4
1-6 Admissible Ambient Conditions.............................................................................1-5
1-7 Functions of Display Controls................................................................................1-5
1-8 Display Indicators ..................................................................................................1-6
1-9 COM 1 Interface Pin Connections.........................................................................1-9
1-10 RS232 Command Table......................................................................................1-10
2-1 Diagnostic Guide ...................................................................................................2-2
2-2 Error Codes ...........................................................................................................2-4
4-1 Test Masses Required ..........................................................................................4-1
4-2 Tolerances – Precision Models .............................................................................4-2
4-3 Tolerances – Analytical Models.............................................................................4-2
4-4 Repeatability Worksheet .......................................................................................4-8
5-1 Precision Top Load Balance Housing & Internal Parts .........................................5-3
5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts .........................5-5
5-3 Square Pan Block Style Square Pan Balance: Housing & Internal Parts..............5-7
5.4 Precision Draft Shield Balance with Draft Shield: Housing & Parts.......................5-9
5.5 Analytical Balance: Housing & Internal Parts ......................................................5-11
5.6 Precision Balance Load Cell & Parts...................................................................5-13
5.7 Analytical Balance Load Cell & Parts ..................................................................5-15
5.8 Block Style InCal Load Cell & Parts ....................................................................5-17
LIST OF ILLUSTRATIONS
FIGURE NO. TITLE
1-1 Pioneer, Carat and Gold Series Displays..............................................................1-5
1-2 Pioneer Display Indicators.....................................................................................1-6
1-3 Pioneer Menu Structure ........................................................................................1-7
1-4 Load Cell Assembly...............................................................................................1-8
1-5 COM 1 Connector .................................................................................................1-9
1-6 Soldering points J1 and J2 ....................................................................................1-9
3-1 Top panel lifts up and slides out............................................................................3-2
3-2 Groove in side panel’s base liner aligns with tab on Housing ...............................3-2
3-3 Precision Load Cell with Incal ...............................................................................3-3
3-4 Analytical Load Cell with Incal...............................................................................3-3
3-5 Precision Load Cell ...............................................................................................3-3
3-6 Analytical Load Cell...............................................................................................3-3
3-7 Precision Block Style Load Cell with InCal............................................................3-4
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TABLE OF CONTENTS
FIGURE NO. TITLE Page No.

3-8 Analytical Block Style Load Cell with InCal ...........................................................3-4
3-9 Precision Balance with InCal Mechanism .............................................................3-4
3-10 InCal Weight Cover removed ................................................................................3-5
3-11 Bottom Housing with Load Cell, Weight Arms and Weights removed...................3-5
3-12 InCal Motor removed from its Housing..................................................................3-6
3-13 Screws securing Weight Arm assembly ................................................................3-6
3-14 Proper manner to grasp Load Cell when removing Weight Arm assembly...........3-7
3-15 Cable connects to Position Sensor Board.............................................................3-7
3-16 Access the 3 screws to release Precision balance Load Cell from top center ......3-7
3-17 Service Fixture, screws and washers for 150g to 310g Precision balances .........3-8
3-18 Service Fixture, screws and washers for 510g to 4100g Precision balances .......3-8
3-19 Precision Load Cell top .........................................................................................3-8
3-20 Precision Load Cell bottom ...................................................................................3-8
3-21 Precision Load Cell (150g to 310g) top, with Service Fixture attached.................3-9
3-22 Service Fixture for 510g to 4100g Precision Load Cell, attached to Hanger.........3-9
3-23 Bent Flexure ..........................................................................................................3-9
3-24 Position Sensor Board.........................................................................................3-10
3-25 Contact Board with ribbon cable .........................................................................3-10
3-26 Fine wires connected to the Contact Board, and affixed to Ratio Beam .............3-10
3-27 Contact Board taped to Ratio Beam after removal from frame ...........................3-11
3-28 Hanger ................................................................................................................3-10
3-29 Two screws secure Magnet Half .........................................................................3-11
3-30 Sideways Motion Stop Plate................................................................................3-11
3-31 Ratio Beam clearing stop on Up/Down Stop Screw as it is lifted out ..................3-12
3-32 Magnets must be clean .......................................................................................3-12
3-34 Adjust position of Sensor Board until Err8.X does not appear ............................3-13
3-36 Installing Ratio Beam, clearing the Up/down Stop Screw ...................................3-15
3-37 Precision Load Cell (150g to 310g) top, with Service Fixture attached...............3-15
3-38 Service Fixture for 510g to 4100g Precision Load Cell, attached to Hanger.......3-15
3-39 Sideways Motion Stop Plate................................................................................3-16
3-40 Two screws secure Magnet Half .........................................................................3-16
3-41 Contact Board .....................................................................................................3-16
3-42 Solder points on Position Sensor Board..............................................................3-16
3-43 Precision Load Cell top .......................................................................................3-17
3-44 Precision Load Cell bottom .................................................................................3-17
3-45 Ratio Beam Flexures and Vertical Flexure..........................................................3-17
3-46 Insert the 3 screws to secure Precision Load Cell in Bottom Housing ................3-17
3-47 When Position Sensor Board shows normal weight, tighten its screws ..............3-18
3-48 Analytical Balance with InCal Mechanism...........................................................3-19
3-49 InCal Weight Covers removed ............................................................................3-19
3-50 Bottom Housing with Load Cell, Weight Arms and Weights removed.................3-20
3-51 InCal Motor removed from its assembly..............................................................3-20
3-52 InCal Motor Cam in correct position for reassembly ...........................................3-20
3-53 Cable connects to the Position Sensor Board.....................................................3-21
3-54 On Analytical balances, the 3 screws securing Load Cell are on bottom............3-21
3-55 Service Fixture, screws and shims for Analytical balances.................................3-22
3-56 Bottom Mounting Plate and Flexure Arms, Analytical balance’s Load Cell.........3-22
3-57 Top Mounting Plate and Flexure Arms, Analytical balance’s Load Cell ..............3-22
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TABLE OF CONTENTS
3-58 Screws removed from Bottom Mounting Plate inserted into the Hanger.............3-23
3-59 Shims are inserted between the Hanger and the Load Cell................................3-23
3-60 Analytical balance Load Cell with Top Bracket visible ........................................3-23
3-61 Vertical Flexure and screws, Lock Plate, washers, and bushings, removed.......3-23
3-62 Top Flexure Arm (Analytical)...............................................................................3-23
3-63 Bottom Flexure Arm (Analytical)..........................................................................3-23
3-64 Hanger with two screws ......................................................................................3-25
3-65 Service Fixture attached to the front of Load Cell after removing Hanger ..........3-25
3-66 The Vane is secured by two screws near the rear of the Load Cell ....................3-25
3-67 The Vane removed..............................................................................................3-25
3-68 Two solder points on PSB, and two screw holes for removing the board ...........3-26
3-69 Contact Board with 3-wire ribbon cable soldered to it .........................................3-26
3-70 Four screws secure the Magnet Half to the Ratio Beam.....................................3-26
3-71 The Magnet Half, when removed, should be cleaned .........................................3-25
3-72 A screw connects the Contact Board to the Load Cell ........................................3-26
3-73 Use a smaller screw to temporarily fasten it to the Ratio Beam..........................3-26
3-74 The Sideways Motion Stop Plate and the black Up/Down Stop screw ...............3-27
3-75 Position Sensor Board (Analytical)......................................................................3-28
3-76 Adjust Position Sensor Board vertically until Err8.X does not appear.................3-28
3-77 The Ratio Beam needs to clear the groove in the Up/Down Stop Screw............3-29
3-78 Service Fixture is installed prior to installing Ratio Beam Flexures.....................3-29
3-79 Sideways Motion Stop Plate and Up/Down Stop Screw .....................................3-29
3-80 Elongated holes on Ratio Beam Flexures go on the bottom ...............................3-29
3-81 Installing the Magnet Half....................................................................................3-30
3-82 Four screws on Magnet Half ...............................................................................3-30
3-84 3-wire cable soldered to Contact Board ..............................................................3-30
3-85 Installing the Vane...............................................................................................3-30
3-86 Screws removed from Bottom Mounting Plate inserted into the Hanger.............3-31
3-87 Insert shims between the Hanger and the Load Cell on both sides ....................3-31
3-88 Bottom Flexure Arm ............................................................................................3-31
3-89 Top Flexure Arm..................................................................................................3-31
3-90 Vertical Flexure ...................................................................................................3-31
3-91 Vertical Flexure and screws, Lock Plate, washers, and bushings, removed.......3-31
3-92 Analytical InCal Load Cell with Top Bracket visible.............................................3-32
3-93 Analytical balance Load Cell with Top Bracket visible ........................................3-32
3-94 Bottom Mounting Plate on Analytical Load Cell ..................................................3-32
3-95 Ribbon cable connects PSB to Main PCB...........................................................3-32
3-96 When Position Sensor Board shows normal weight, tighten its screws ..............3-33
3-97 Block Style Load Cell ..........................................................................................3-34
3-98 Service Toolset for Block Style Load Cells. PN 476000-030 .............................3-35
3-99 InCal Motor..........................................................................................................3-36
3-100 InCal Motor Removal...........................................................................................3-36
3-101 Motor Coupler .....................................................................................................3-36
3-102 Motor Shaft in counter-clockwise position ...........................................................3-37
3-103 Mounting Screws holding InCal Mechanism .......................................................3-37
3-104 Removing the InCal Mechanism .........................................................................3-37
3-105 InCal Mechanism Alignment................................................................................3-38
3-106 Centering InCal Weight .......................................................................................3-38
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TABLE OF CONTENTS
3-107 Removing Position Sensor ..................................................................................3-39
3-108 Ratio Beam Pin Alignment ..................................................................................3-39
3-109 Base Plate Removal............................................................................................3-40
3-110 Load Cell Mounting Components ........................................................................3-41
3-111 Load Cell Alignment to Base Plate......................................................................3-41
3-112 Block Style Load Cell PC Board Item Locations .................................................3-42
3-113 Block Style Load Cell PC Board Removed from Load Cell .................................3-42
3-114 Load Cell PCB-Temperature Sensor-Position Sensor assembly ........................3-43
3-115 Position Sensor ...................................................................................................3-43
3-116 Removing Temperature Sensor ..........................................................................3-43
3-117 Load Cell PCB.....................................................................................................3-44
3-118 Contact Board Cover is removed by squeezing the plastic post .........................3-44
3-119 Contact Board with cover holder off ....................................................................3-44
3-120 Centering Pins.....................................................................................................3-44
3-121 Centering Pins Installed ......................................................................................3-44
3-122 Contact Board Location.......................................................................................3-45
3-123 Contact Board with cover holder off ....................................................................3-45
3-124 Loosening Ratio Beam Nuts................................................................................3-45
3-125 Ratio Beam Screws and Washers removed........................................................3-45
3-126 Loosening InCal Weight Arm nuts.......................................................................3-46
3-127 Weight Arm Screws and Washers removed........................................................3-46
3-128 InCal Weight Arm removal ..................................................................................3-46
3-129 InCal Weight Arm removed .................................................................................3-46
3-130 Aluminum Sleeves removed................................................................................3-47
3-131 Up/Down Stop Screw ..........................................................................................3-47
3-132 Centering Pins removed......................................................................................3-47
3-133 Removing the Ratio Beam ..................................................................................3-47
3-134 Ratio Beam Removed .........................................................................................3-47
3-135 Removing the Ratio Beam ..................................................................................3-47
3-136 Ratio Beam Removed .........................................................................................3-47
3-137 Removing the Aluminum Sleeves .......................................................................3-47
3-138 Ratio Beam Weight Removal ..............................................................................3-48
3-139 Load Cell Critical Area.........................................................................................3-48
3-140 Magnet Area........................................................................................................3-48
3-141 Ratio Beam Vane Slotted Area ...........................................................................3-49
3-142 Four Ratio Beam sleeves are larger than the four Weight Arm sleeves .............3-49
3-143 Replacing the Ratio Beam...................................................................................3-49
3-144 Positioning the Ratio Beam over the Magnet ......................................................3-49
3-145 Centering Pin goes into first hole after upward bend in Ratio Beam...................3-49
3-146 InCal Weight Arm before insertion ......................................................................3-50
3-147 Inserting InCal Weight Arm .................................................................................3-50
3-148 Weight Arm must be lifted slightly to insert Centering Pin...................................3-50
3-149 Proper method for tightening nuts while holding screw head stationary .............3-50
3-150 Centering pins in Ratio Beam..............................................................................3-51
3-151 Tightening Ratio Beam nuts ................................................................................3-51
3-153 Repositioning the Contact Board and Screw.......................................................3-51
3-154 Load Cell PCB, Temperature Sensor and Position Sensor.................................3-52
3-155 Groove on left of PCB fits tab on Load Cell frame ..............................................3-52
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TABLE OF CONTENTS
3-156 Temperature Sensor extends into a hole in the Magnet .....................................3-52
3-157 Position Sensor on the Magnet ...........................................................................3-53
3-158 Pin centered in PSB ............................................................................................3-53
3-159 Load Cell PCB Test Connector ...........................................................................3-54
3-160 Test Connector Detail..........................................................................................3-54
4-1 Segment Display ...................................................................................................4-1
4-2 Mass Placement Locations for Off-Center Load Test ...........................................4-3
4-3 Off-Center Load Adjustment Screws on Analytical models...................................4-4
4-4 Off-Center Load Adjustment Screws on Precision models ...................................4-4
4-5 Off-Center Load Adjustments................................................................................4-4
5-1 Precision Top Load Balance Housing & Internal Parts..............................................5-2
5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts..............................5-4
5-3 Square Pan Block Style Square Pan Balance: Housing & Internal Parts ..................5-6
5.4 Precision Draft Shield Balance with Draft Shield: Housing & Parts ...........................5-8
5.5 Analytical Balance: Housing & Internal Parts ..........................................................5-10
5.6 Precision Balance Load Cell & Parts .......................................................................5-12
5.7 Analytical Balance Load Cell & Parts ......................................................................5-14
5.8 Block Style InCal Load Cell & Parts.........................................................................5-26
C-1 Com Port Configuration Menu.............................................................................. C-1
C-2 The Software Service Tool’s Restore EEProm Tab ............................................. C-2
C-3 The Software Service Tool’s Replace Load Cell Tab........................................... C-3
C-4 The Software Service Tool’s Replace PCB Tab................................................... C-4
C-5 The Software Service Tool’s Download Software Tab ......................................... C-5
C-6 The Software Service Tool’s Diagnostics Tab...................................................... C-6
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TABLE OF CONTENTS
Pioneer™ Balances Service Manual viii Ohaus Corporation www.ohaus.com

1.1 INTRODUCTION
This service manual contains the information needed to perform routine maintenance and
service on the Ohaus Pioneer Precision and Analytical balances. The contents of this manual
are contained in five chapters:
Chapter 1 Getting Started – Contains information regarding service facilities, tools and test
equipment, measuring masses, specifications, and the mechanical and electronic functions of
the balance.
Chapter 2 Troubleshooting – Contains a diagnosis/diagnostics chart and error code table.
Chapter 3 Maintenance Procedures – Contains preventive maintenance procedures and

disassembly, repair and replacement procedures.
Chapter 4 Testing – Contains an operational test, segment display test, performance tests and
adjustments.
Chapter 5 Drawings and Parts Lists – Contains exploded views of Pioneer balances and
Load Cells identifying all serviceable components.
Before servicing the balance, you should be familiar with the Instruction Manual which is packed
with every balance.
1.2 SERVICE FACILITIES
To service a balance, the service area should meet the following requirements:
• Should be temperature controlled and meet the balance specifications for temperature
environmental requirements. See specifications for temperature ranges of the various
models.
• Must be free of vibrations such as fork lift trucks close by, large motors, etc.
• Must be free of air currents or drafts from air conditioning/heating ducts, open windows,
people walking by, fans, etc.
• Area must be clean and air must not contain excessive dust particles.
• Work surface must be stable and level.
• Work surface must not be exposed to direct sunlight or radiating heat sources.
• Use an approved Electro-Static Device.
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1.3 TOOLS AND TEST EQUIPMENT REQUIRED

1.3.1 Special Tools
1. Fixture P/N 923345 Corp. Item No. 00923345 for use with 150g to 410g Load Cells.
2. Fixture P/N 923389 Corp. Item No. 00923389 for use with 510g to 4100g Load Cells.
3. Fixture P/N 476001-020 Corp. Item No. 80250050 for use with analytical load cells.
4. Block Style Fixture P/N 476000-030 Corp. Item No. 80250383
1.3.2 Standard Tools and Test Equipment

1. Digital Voltmeter (DVM) – Input impedance at least 10 megohms in 1 V DC position.
2. Nutdriver, 6mm
3. Hex or Allen key wrenches, metric.
4. Other assorted hand tools, tweezers, adjustable open wrenches, etc.
5. Soldering iron (50 watt) and solder (rosin core solder, not acid core).
6. Solder remover.
1.4 SPECIFICATIONS
Complete specifications for the Ohaus Pioneer Balances are listed in Tables 1-1 – 1-5.
When a balance has been serviced, it must meet the specifications listed in the table.
Before servicing the balance, determine what specifications are not met.
TABLE 1-1. SPECIFICATIONS: EXTERNAL CALIBRATION MODELS (includes M Models)

MODEL PA64 PA114 PA214 PA153 PA213 PA313 PA413 PA512 PA1502 PA2102 PA4102 PA4101
Capacity (g) 65 110 210 151 210 310 410 510 1510 2100 4100 4100
Readability (g) 0.0001 0.001 0.001 0.01 0.1
Repeatability (mg) 0.1 (std. dev.) 1 1 (std. dev.) 10 (std. dev.) 100 sd
Linearity (g) ±0.0003 ±0.003 ±0.03 ±0.3
OCL ½ cap ½ dist 0.1mg 0.2 mg 0.3 mg 3 mg 30 mg 40 mg 200 mg
Tare Range To capacity by subtraction
Stabilization 3 Seconds
50 or 50 or 100 or 100 or 100 or 200 or 200 or 200 or 1000 or 1000 or
Span Cal Mass (g) 2000 or 4000
60 100 200 150 200 300 400 500 1500 2000
20, 50, 100, 100, 100, 150, 200, 200, 1000, 1000,
Lin. Cal Mass (g) 2000, 4000
50 100 200 150 200 300 400 500 1500 2000
Pan Diameter 3.5 in / 9 cm 4.7 in / 12 cm 7.1 in / 18 cm
Net Wt 10 lb / 4.5 kg 7.3 lb / 3.3 kg
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1.4 SPECIFICATIONS
TABLE 1-2. SPECIFICATIONS: INCAL MODELS (C & CM)

MODEL PA64C PA114C PA214C PA213C PA413C PA512C PA2102C PA4102C PA4101C
Max (g) 65 110 210 210 410 510 2100 4100 4100
Min (g) 0.1 0.2 5
d = (g) 0.0001 0.001 0.01 0.1
e = (g) 0.001 0.01 0.1
Approval Class 1 Class 2
Repeatability (mg) 0.1 (std. dev.) 1 (std. dev.) 10 (std. dev.)
Linearity (g) ±0.0003 ±0.003 ±0.03
OCL ½ cap ½ dist 0.2mg 0.3mg 2mg 3mg 20mg 30mg
50 or 100 or 100 or 200 or 1000 or
Span Cal Mass (g) 50 or 60 200 or 400 2000 or 4000
100 200 200 500 2000
Pan Diameter 3.5 in / 9 cm 4.7 in / 12 cm 7.1 in / 18 cm
Net Wt 10 lb / 4.5 kg
TABLE 1-3. SPECIFICATIONS: CARAT MODELS

MODEL PAJ303 PAJ303C PAJ603 PAJ603C PAJ1003 PAJ1003C PAJ2003 PAJ2003C
Capacity (g) 65 120 210 400
Readability (g) 0.001 0.01
Repeatability (mg) 0.1 (std. dev.) 1 (std. dev.)
Linearity ±0.003 ±0.003 ±0.03
OCL ½ cap ½ dist 0.2mg 0.1mg 0.2mg 0.3mg 0.2mg
InCal or InCal or InCal or 200 or InCal or
Span Cal Mass (g) 50 or 60 50 or 100 100 or 200
50 or 60 50 or 100 100 or 200 400 100 or 150
Lin. Cal Mass (g) 20, 50 X 50, 100 X 100, 200 X 200, 400 X
Pan Diameter 3.5 in / 9 cm 4.7 in / 12 cm

1.4 SPECIFICATIONS
TABLE 1-4. SPECIFICATIONS: GOLD MODELS (EXTERNAL CALIBRATION)

MODEL PAJ812 PAJ2102 PAJ3102 PAJ4102 PAJ2101 PAJ3101 PAJ4101
Capacity (g) 810 2100 3100 4100 2100 3100 4100
Repeatability (g) 0.01 (std. dev.) 0.1 (std. dev.)
Linearity (g) ±0.03 ±0.2
OCL ½ cap ½ dist 0.3mg 0.4mg 2mg
1000 or 2000 or 2000 or 1000 or 2000 or 2000 or
2000 3000 4000 2000 3000 3000
500, 2000, 2000, 1000, 2000,
Lin. Cal Mass (g) 1000, 2000 2000, 3000
800 3000 4000 2000 4000
Pan Diameter 6.6 x 7.1 in / 16.8 x 18 cm
TABLE 1-5. SPECIFICATIONS: GOLD MODELS (INTERNAL CALIBRATION)

MODEL PAJ812C PAJ2102C PAJ3102C PAJ4102C PAJ2101C PAJ3101C PAJ4101C
Capacity (g) 510 2100 3100 4100 2100 3100 4100
Repeatability (g) 0.01 (std. dev.)
Linearity (g) ±0.03 ±0.03 ±0.03 ±0.03
1000 or 2000 or 2000 or 1000 or 2000 or 2000 or
2000 3000 4000 2000 3000 4000
Lin. Cal Mass (g) X X X X X X X
Pan Diameter 6.6 x 7.1 in / 16.8 x 18 cm
Net Wt 10.0 lb / 4.5 kg

1.4 SPECIFICATIONS
TABLE 1-6. ADMISSIBLE AMBIENT CONDITIONS

Temperature range 50°F to 86°F / 10°C to 30°C
Atmospheric humidity 80% rh @ to 30°C
Voltage fluctuations -15% +10%
Installation category II
Pollution degree 2
Power supply voltage 8-14V ac, 50/60 Hz, 6VA or 9.5-20V dc, 6W
Use only in closed rooms.
1.5 BALANCE OPERATION

This section contains information on the basic operation of the balance, and mechanical
descriptions of the Load Cell. Exploded view drawings are included in Chapter 5, which
identifies all replaceable components of the balance.
Allow one hour for each 5° F or 3° C temperature change before using the balance. Following
temperature stabilization, allow an additional hour after turning the balance on, for the balance
to stabilize.
1.5.1 OVERVIEW OF THE CONTROLS
Figure 1-1. Pioneer, Carat and Gold Series displays.

1.5.2 OVERVIEW OF THE CONTROLS
TABLE 1-7. FUNCTIONS OF DISPLAY CONTROLS

Button Action Functions
O/T – On Short Press: Turns balance on, sets display to zero
Off Long Press: Turns balance off
Yes Short Press (Menu mode): Selects or accepts setting
Unit Short Press: Steps through active units and modes
Menu Long Press: Enters Menu
No Short Press (Menu mode): Steps through available settings
Long Press (Menu mode): Exit menu or abort out of menu item
Print Short Press: Sends data
Cal Long Press: Initiates Span Calibration
1.5.2 OVERVIEW OF THE DISPLAY INDICATORS
5
2
Figure 1-2. Pioneer Display Indicators.

3 4
TABLE 1-8. DISPLAY INDICATORS
No. Function
1 Indicates that the measured value has become stable.
2 Negative Indicator
3 Center of Zero Indicator
4 Standard (7) segment numeric characters. Eight characters are available and are used for
displaying weight values.
5 Symbols for weighing modes, include:
g - Grams, kg - Kilograms, mg - Milligrams, ct- Carats, N - Newtons, lb - Pounds,
oz - Ounces, oz t - Ounces troy, GN - Grain, dwt - Pennyweight, mo - Mommes,
m - Mesghal, t - Taels. (Taels are available in three types; Hong Kong, Singapore, and Taiwan),
cl - Tical, PCS - Parts counting.

1.5.3 Power ON
Press >O/T<. All segments will appear briefly followed by a software revision number
(when plugged in first time, or after a power interruption), and then * 0.00g.
Allow one hour warm-up time. The balance should be calibrated before use.
1.5.4 Power OFF
To turn the balance OFF, press and hold >O/T< until the display indicates OFF, then release.
1.5.5 Menu Setup
Programmable features of the Pioneer balances are contained in menus which are accessed
through the Display Panel’s control switches. See the Instruction Manual for a full description of
the menus and how to access them.
1.5.6 Menu Structure
Figure 1-3. Pioneer Menu Structure
ENTER MENU – When the balance is on, press and hold Unit/Menu until mMENU appears.
Release the button and the Calibrate [.CAL.] menu will display.
MENU NAVIGATION – To select menus, menu items and settings, press Yes or No. Solid
arrows point to content displayed when Yes is pressed, dashed lines when No is pressed.
CHANGE SETTINGS – To select the displayed setting, press Yes. To move to the next setting,
press No.
EXIT MENU – When [.END.] appears, press Yes to exit the menu function, or No to return to
the Cal menu. Note: Press and hold No at any time to exit quickly.

1.5.7 The Load Cell
Figure 1-4 illustrates a typical Magnetic Force Restoration (MFR) Load Cell.
The force of a weight placed on the Weighing Pan moves the Hanger which is guided by the
Upper and Lower Flexure Arms. The Load Flexure transfers the force vertically to the Ratio
Beam. The Ratio Beam Flexures form a pivot for the Ratio Beam. When the Ratio Beam is
moved, the Force Coils mounted on the Ratio Beam are moved. The Force Coils are located in
the magnetic field created by the Permanent Magnets. The magnetic forces are affected by
temperature. A Temperature Sensor is attached near the magnets to measure the temperature
and allow the electronics to compensate for the changes in temperature.
Operation
A mass placed on the Pan applies a downward force to the Load Flexure by means of the
Hanger. The Load Flexure moves one end of the Ratio Beam which pivots, moving the Force
Coil up into the air gap of the Magnet. The Force Coils are located in the field of the Permanent
Magnets. The movement of the Vane (which is connected to the Ratio Beam) is detected by the
Position Sensor. The Position Sensor contains a sender and receiver. When the Vane moves,
the amount of light sent to the receiver also changes. The change in the position of the Sensor
Vane is measured and used along with the Temperature Sensor signal to adjust the current in
the Force Coils. The current in the Force Coils produces a magnetic field which restores the
Ratio Beam to its normal position.
Ratio
Beam Pan
Counter
Vane Force
Weight
Coils Upper Flexure Arm
Position Top Bracket
Sensor
Hanger
Temperature Ratio Beam
Sensor Flexure
Printed Circuit
Board Vertical
Flexure
Magnet Bottom Flexure Arm Flexure
Figure 1-4. Load Cell Assembly.

1.6 Connecting the RS232 Interface
When the interface is connected to a computer, two-way communication between the computer
and balance is possible using the commands outlined in the RS232 Command Table 1-10.
RS232 Commands
All communication is accomplished using standard ASCII format. Only the characters shown in
the RS232 Command Table 1-10 are acknowledged by the balance. Invalid command
response "ES" error indicates the balance has not recognized the command. Commands sent
to the balance must be terminated with a carriage return (CR) or a carriage return-linefeed
(CRLF). Data output by the balance is always terminated with CRLF.
On the rear of the balance, the 9-pin female subminiature "D" connector COM 1, is provided for
interfacing to other devices. The pin connections are shown in the illustration below.
TABLE 1-9. COM 1 INTERFACE PIN CONNECTIONS

COM 1 Pin Connections
1 – Remote Tare
Zero/Tare* J1*
2 – TxD
3 – RxD
5 4 3 2 1 Print* J2* 4 – Not used
9 8 7 6 5 – Ground
6 – Not used
7 – CTS
Figure 1-5. COM 1 Connector.
8 – RTS
9 – Remote Print
*External PRINT and/or ZERO/TARE switches may be installed as shown in the diagram.
Use only momentary contact switches.
To enable External PRINT and/or ZERO/

TARE functions, join the solder points for Tare
(J1) and Print (J2), on the Main PCB:
1. Locate solder points J1 and J2 on the
Main PCB, adjacent to the RS232 input
jack.
2. Using a low wattage soldering iron,
apply a small amount of solder to:
– Join two points at J1 to enable Tare.
– Join two points at J2 to enable Print.
Join the points by filling the gap:
Figure 1-6. Soldering points J1 and J2.

1.7 RS232 Commands
Commands listed in the following table will be acknowledged by the balance. The balance will
return "ES" for invalid commands.
TABLE 1-10. RS232 COMMAND TABLE

Command Function
IP Immediate print the displayed weight (stable or unstable).
P Print and displayed weight (stable or unstable).
CP Continuous Print. OP ends continuous print.
AS Auto print on stability
xP Interval Print x = Print Interval (1-3600 seconds) OP ends Interval Print.
T Same as pressing Zero/Tare key.
PU Print current weighing unit.
OFF Turns balance OFF.
ON Turns balance on.
PSN Print Serial Number.
PV Print version: name, software revision and LFT ON (if LFT is set on).
x# Set PC reference weight (x) in grams. (Must have been a APW stored.)
P# Print PC reference weight.
x% Sent % reference weight (x) in grams. (Must-have reference weight stored.)
P% Print percent reference weight.
0PF Stop (zero) the old Adventurer print format, begin to use the default print format
1PF Stop using the default print format, begin to use the old Adventurer print format
0S (zero) Stable off
SS Stable on (default)
0RL Stops the scale from sending “OK” in response to instruction (non-print) commands.
1RL Returns scale to default mode of sending “OK”.

CHAPTER 2 DIAGNOSTIC GUIDE
2.1 TROUBLESHOOTING
This section of the manual provides guidelines for evaluating the condition and performance of a
balance, and a standard troubleshooting methodology to follow. Follow all directions step by
step. Make certain that the work area is clean. Handle balance components with care. Use an
appropriate Electro-Static Device.
2.1.1 General Procedures for Troubleshooting

1. Do the most obvious, user-level remedies.
2. Perform Ramp check and Service Calibration.
3. Check that internal parts are clean and free of debris.
4. Inspect the motion of the Ratio Beam: it should move up and down freely.
If not, determine if the cause is mechanical binding, or electrical malfunction.
5. Make an electrical check of the Ratio Beam: measure the resistance of the coils
in the Ratio Beam.
6. Check the InCal Mechanism (if applicable). It should move up and down smoothly.
7. Inspect the Load Cell components. Be sure they are clean and that no Flexures are
bent. (If they are, they must be replaced.)
2.2 DIAGNOSTIC GUIDE
Table 2-1 is a Diagnostic Guide designed to help locate the problem area quickly and easily.
The probable causes are listed with the most common cause first. If the first remedy does not
fix the problem, proceed to the next remedy. Before attempting to repair the balance, read all
chapters of this manual to be familiar with the balance components and operation.
2.2.1 Diagnosis
1. Isolate and identify the symptom
2. Refer to Table 2-1, Diagnostic Guide and locate the symptom.

Also consult Table 2-2, Error Codes, for solutions to specific Errors.
3. Follow the suggested remedies in the order they appear.
4. Perform the indicated checks, as summarized in the Section 2.4, General

Troubleshooting Procedures, or see the appropriate section of the manual.
5. Repair or replace the defective part of the balance.
NOTE:
If more than one symptom is observed, approach one area at a time,
and remember that the symptoms may be interrelated.
If a problem arises that is not covered in this manual, contact Ohaus Corporation for further
information.
Pioneer™ Balance Service Manual 2-1 Ohaus Corporation www.ohaus.com

2.2.1 Diagnosis
TABLE 2-1. DIAGNOSTIC GUIDE

SYMPTOM PROBABLE CAUSE REMEDY
Balance will not turn Main power source is off Check the main power source outlet for
on with AC adapter proper voltage.
supplied
Adapter defective Check the AC adapter voltage output
which should match the specified
voltage on the adapter. If voltage is
low or nonexistent, replace the AC
adapter. If OK, proceed.
Input connector at rear of Open the balance. Leave the cable
Balance may be defective connected to the Top Housing.
Reconnect the AC adapter. Check AC
voltage at the input connector
terminals. It should read 12 V AC. If
voltage is not present, replace the input
connector. If OK, proceed.
Main PC Board defective. Replace the Main PC Board.
Balance does not Main PC Board is defective Replace the Main PCB.
respond to front panel
controls.
Poor accuracy. Unstable environment. Move balance to suitable location;

ensure that balance is level.
Balance out of calibration. Calibrate the balance.
Balance was not re-zeroed Press >O/T< with no weight on the pan,
before weighing. then weigh item.
Balance can be turned Incorrect weights. Verify that proper weights are used.
on but will not calibrate
manually.
Balance not level. Level the balance.
Balance is unstable. Perform Automatic Internal Calibration.
(See Appendix A.1.)
Enter Service mode (Appendix B) and
perform a Span Calibration. If this fails,
check the InCal Weight Assembly and
the Load Cell Assembly. Ensure that
all parts are clean and properly aligned.
Load cell assembly Repair the Load Cell.
defective. (See Chapter 3.)
PCB is defective. Replace the PCB.

TABLE 2-1. DIAGNOSTIC GUIDE

SYMPTOM PROBABLE CAUSE REMEDY
Balance will not Unstable environment. Move the balance to a location without
calibrate using internal draft or vibration.
calibration, but InCal Mechanism may be Level the balance using leveling feet on
calibration motor is misaligned, or not moving rear of chassis, together with leveling
working. smoothly. bubble.
Use software tool to test mechanism.
(See Section C.5.1, Appendix C.)
To correct problem, see Section 3.3.
Calibration Motor is Calibration Motor may be Remove the Calibration Motor;

not working. defective check the Calibration Motor with
software tool (See Section C.5.1,
Appendix C.), replace if defective.
If motor is OK, continue with testing
entire assembly.
Load Cell Motor Assembly With motor removed, move the InCal
jammed. Mechanism by hand. If binding is
found, replace Mechanism.
Main PC board is defective. Verify that all other functions are
operational. If functions are OK, the
Main PC board is defective.
Test the balance for proper functions
and calibration.
Unable to display Weighing Balance not Use Units menu to set desired units.
weight in a particular enabled in menu
weighing Balance.
Unable to access a Mode not enabled in menu

particular mode

2.3 ERROR CODES
When a problem occurs using the balance, the display will indicate an error code.
Table 2-2 describes the various error codes and specifies the probable cause and remedy.
TABLE 2-2. ERROR CODES

ERROR PROBABLE CAUSE REMEDY
Err 5 Average Piece Weight too small. Add additional samples.
Err 7.0 Time out after delay in Power on Press Off, then press On.
or menu item selection.
Perform Troubleshooting measures.
(See Section 2.1.1.)
Err 8.1 Pan has load during power on. Remove weight from Pan and re-zero.
Perform Troubleshooting steps.
Err 8.2 Pan was removed prior to power Install Pan and re-zero.
on. Perform Troubleshooting steps.
Err 8.3 Weight on Pan exceeds Remove weight from Pan.
capacity. Perform Troubleshooting steps.
Err 8.4 Pan was removed during Re-install Pan.
weighing. Perform Troubleshooting steps.
Err 9.5 Factory calibration data Perform Service Calibration.
corrupted. (See Appendix B.)
Err 9.8 Factory calibration data Perform Service Calibration.
corrupted. (See Appendix B.)
Error 53 Cable from Load Cell to Main Replace cable.
PCB disconnected or damaged
EEPROM Checksum error. Restore EEPROM. (See Appendix C.)
REF Err Reference weight is too small. Add additional samples.
(See Instruction Manual.)
LOWrEF Reference weight is too low for Add additional samples or continue to
accurate parts counting or weigh with less accurate results.
percent weighing.
––––––– Unstable weight reading Check environment: area should be
free of vibrations, air currents or drafts,
and temperature should meet the
balance specifications.
Perform Troubleshooting measures.

3.1 PREVENTIVE MAINTENANCE
Ohaus balances are precision instruments and should be carefully handled, stored in a clean,
dry, dust-free area, and cleaned periodically. Follow these precautionary steps:
– When a balance has had chemicals or liquids spilled on it, all exterior surfaces should be
cleaned as soon as possible with warm water on a damp cloth.
– Do not leave a mass on the balance when the balance is not in use.
– Allow time for the balance to stabilize after moving it from an area which is at a different
temperature than the area where it is to be operated. Allow one hour for each 5° F or
3° C temperature change before using the balance. Following temperature stabilization,
allow an additional hour after connecting power to the balance, for the balance to
stabilize.
3.1.1 Preventive Maintenance Checklist
The balance should be inspected and checked regularly, as follows:
1. Remove the Pan and Pan Support to inspect and clean the area beneath the Pan.
2. Clean the outside of the balance using a damp cloth with warm water.
CAUTION
DO NOT USE CHEMICAL CLEANERS OR SOLVENTS OF ANY TYPE.
SOME CLEANERS ARE ABRASIVE AND MAY AFFECT THE BALANCE’S
FINISH.
3. Check the Power Cord for broken or damaged insulation.
4. Make a visual inspection for faulty connectors, wiring, and loose hardware.
3.2 OPENING THE BALANCE
Opening the Pioneer balance varies slightly according to the specific model, as detailed below.
Differences are detailed in the text. Use these procedures in order to:
– Replace Printed Circuit Boards
– Replace bent or broken Flexures
– Gain access to the Load Cell for removal, cleaning, parts replacement and alignment.

3.2.1 Variations in Opening Pioneer Models
Turn the balance off and unplug the power cord before you begin.
Preliminary Steps:
For a balance with a Draft Shield:
1. Remove the Draft Shield components from the balance:
– Remove the top panel: lift its plastic handle and slide it forward to remove it.
(See Figure 3-1.)
– Remove the side doors: when they are closed, a groove in the plastic door guide
aligns with the tab on the Housing. (See Figure 3-2.) Align the groove and lift
the panel straight up, then out and down to disengage it from the top.
– To remove the front and back panels, press on the tab in the middle of the top
frame and gently press the panel out.
Figure 3-1. Top panel lifts up and slides out. Figure 3-2. Groove in side panel’s door guide
aligns with tab on Housing.
2. Remove the Weighing Pan.

For a balance without a Draft Shield:
1. Remove the Weighing Pan and Pan Support.
After completing the preliminary steps, turn the balance over and remove two screws from the
rear, and one near the front, under a plastic sliding tab. Lift off the Top Cover. Then lift off the
Load Cell cover. You now have access to all components of the balance.

3.3 LOAD CELL REMOVAL AND DISASSEMBLY

The Load Cell may need to be removed and repaired because of balance instability, or because
the balance does not calibrate or repeat, or because the balance is physically broken or
displays an error code. The ratio coil may have a short circuit. Possible causes of Load Cell
problems include: parts being misaligned, bent or broken Flexures, contamination or debris, or
in any moving part.
3.3.1 Variations in Pioneer Load Cells

Pioneer balances have different types of Load Cell. Use the illustrations below to identify the
type used in the balance being serviced.
Precision & Analytical Load Cells have different style Flexure Arms.
Figure 3-3. Precision Load Cell with InCal: Figure 3-4. Analytical Load Cell with InCal:
Section 3.3.2, p. 3-5. Section 3.3.6, page 3-7.
Figure 3-5. Precision Load Cell: Figure 3-6. Analytical Load Cell:
Section 3.3.6, page 3-7. Section 3.3.14, page 3-20.
For Block Style Load Cells, see next page

3.3.1 Variations in Pioneer Load Cells
Figure 3-7. Precision Block Style Load Cell Figure 3-8. Analytical Block Style Load Cell
with InCal: Section 3.3.11, page 3-28. with InCal: Section 3.3.11, page 3-28.
3.3.2 Disassembly of Precision Balances with Internal Calibration
Precision balances that have InCal require additional disassembly procedures. (See Section
3.3.2, page 3-4.) This section explains the additional steps required to disassemble, service
and reassemble the Precision balances with InCal mechanism.
Figure 3-9 shows the balance with Top Cover and Load Cell Cover removed.
InCal Motor Screws in InCal

Weight Cover
Screws in InCal
Weight Cover
Figure 3-9. Precision Balance with InCal Mechanism.

3.3.3 Removing Internal Calibration Weights

Follow these steps to remove the InCal Weight Covers, and Weights:
1. Remove the screws that InCal
hold the Weight Covers on Weights
both sides of Load Cell.
2. Lift off the Weight Covers,
and lift out each of the
Weights. (See Figure 3-10.)
3. Remove the Load Cell:
Remove the three screws
holding the Load Cell in
place, as shown in Figure
3-16, on page 3-7.
4. Lift out the Load Cell from
the base. Be careful not to Figure 3-10. InCal Weight Cover removed.
touch the top or bottom
Flexure Arms. If Load Cell is to be disassembled see Section 3.3.2.
3.3.4 Servicing the Internal Calibration Mechanism
1. Follow the steps in Section

3.3.3, to remove InCal
Weights and Load Cell.
2. Remove the two screws

that secure the Weight
Lifter to the base.
(See Figure 3-11.)
3. Take out the Weight Lifter.

that secure the InCal
Motor Assembly.
5. Lift out the InCal Motor

Assembly. Carefully free Screws holding
the InCal Motor's ribbon Weight Lifters
cable from the groove in
the Housing. (Disconnect
the cable’s plug from the
PCB on the front of the
balance.) Figure 3-11. Bottom Housing with Load Cell,
Weight Arms and Weights removed.

3.3.4 Servicing the Internal Calibration Mechanism
6. Remove the screws and washers

that secure the InCal Motor.
Note: Before reinstalling the InCal

mechanism, be sure all of its
components are clean and free of
debris. If the InCal Motor or its Cam
is defective, it must be replaced.
Figure 3-12. InCal Motor removed from its assembly.

3.3.5 Reassembling the Internal Calibration Mechanism
1. Insert the InCal Motor’s cam in the hole of the InCal Motor Assembly Insert the four
screws that hold the motor to the assembly and tighten them.
2. Mount the InCal Motor Assembly in the Bottom Housing. Carefully place the motor’s
ribbon cable in the groove in the Housing, and thread it beside the RS 232 cable
along the outside of the Housing. Insert its plug in the PCB. Then insert and tighten
the screws that hold the assembly to the Housing.
3. Position the Weight Lifter frame as in Figure 3-11, insert and tighten the screws
holding it to the Housing. (To reassemble Precision Load Cells, see Section 3.3.11.)
4. After installing the Load Cell, place Weights in Weight Holders, and test the InCal
mechanism: see Appendix C, Section C.5.1, Incal Weight Mechanism Testing.
3.3.6 Disassembly of Precision Balances with InCal Mechanism
1. Remove the Load Cell, as
described in Section 3.3.3.
2. Turn the Load Cell over,
so the Weight Arm
assembly is visible.
(See Figure 3-13.)
Screws
holding
Weight
Arm
Figure 3-13. Screws securing Weight Arm assembly.

3.3.6 Disassembly of Precision Balances with InCal Mechanism

3. Hold the top and bottom of the
Hanger when removing the Weight
Arm assembly as illustrated in
Figure 3-14.
Note: Avoid touching the top and
bottom Flexure arms.
4. Very carefully remove the screws
shown in Figure 3-13, and lift off
the Weight Arm assembly, while
continuing to hold the Hanger. Figure 3-14. Proper manner to grasp Load
Cell when removing Weight Arm assembly.
5. When reinstalling the InCal Weight
Arm assembly, follow Steps 1
through 5, in reverse.
3.3.7 Removing the Load Cell – Precision Balances without Internal Calibration
1. Open the balance, as explained in

Section 3.2.1.
2. Carefully unplug the cable that

connects the Main PCB to the
Position Sensor Board.
(See Figure 3-15.)
3. Remove the three screws holding

the Load Cell in place – recessed in Figure 3-15. Cable connects to Position
the middle of the Load Cell. Sensor Board.
(See Figure 3-16.)
4. After removing the three screws,

carefully lift the Load Cell out of
the base.
It is now possible to disassemble the Load Cell

for cleaning, alignment, or replacing parts.
Figure 3-16. Access the 3 screws to release

Precision balance Load Cell from top center.

3.3.8 Load Cell Disassembly – Precision Balances
The following steps require the Service Fixture for the Load Cell you will be disassembling.
Note:
Do not attempt repairs without the correct fixture.
Figure 3-18. Service Fixture, screws and

Figure 3-17. Service Fixture, screws and washers for 510g to 4100g Precision
washers for 150g to 310g Precision balances. balances. (Readability = 0.01g to 0.1g.)
(Readability = 0.001g.) PN 923345. PN 923389.
1. Install the Service Fixture on the front of the Load Cell, using the six screws supplied
with the Fixture – tighten screws finger-tight until completing next step.)
(See Figures 3-21 and 3-22.)
Ratio Beam Flexures Ratio Beam Flexures
Vertical
Flexure
Figure 3-21. Service Fixture for 150g to Figure 3-22. Service Fixture for 510g to 4100g
410g Precision Load Cell, attached to Precision Load Cell, attached to Hanger, Ratio
Hanger, Ratio Beam, and Load Cell frame. Beam, and Load Cell frame.

2. Loosen (do not remove) the two screws shown in Figures 3-19 and 3-20 that secure
the top and bottom Flexure Arms at the end closest to the Position Sensor Board.
Flexure
Arm
Screws
closest
to
Position
Sensor
Board
Figure 3-19. Precision Load Cell top. Figure 3-20. Precision Load Cell bottom.
3. Remove the two screws and washers that secure the Vertical
Flexure, and remove the Vertical Flexure.
4. Remove the two screws and washers that secure each Ratio
Beam Flexure, and remove the Flexure.
5. Remove the four screws and washers on the Top Flexure

Arm, and remove it. (Don’t loosen the screws that secure the
Flexure to the Flexure Arm.)
6. Turn the Load Cell over and remove the four screws and
washers on the Bottom Flexure Arm. Carefully remove it.
NOTE:
When handling the Flexure Arms, do not bend the Flexures.
7. Carefully examine each Flexure to see if it is bent. (See

Figure 3-23.) If uncertain, place the Flexure on a clean flat
surface and check that both sides rest evenly on the surface.
If a Flexure is bent even slightly, it must be replaced. Figure 3-23. Bent
Flexure.


8. Unsolder and remove the four wires
shown in Figure 3-24. The two wires
at the bottom connect to the light
source. They must be re-soldered as
pictured here: white on left, red on
right. The two wires on the top
connect to the Temperature Sensor.
Their positions are not important.
Screws holding
11. Remove the three screws holding the Position Sensor Board
Position Sensor Board in place. Solder
points
(The two on the right have washers.
The one on the left doesn’t.) Figure 3-24. Position Sensor Board.
12. Gently set the Position Sensor Board aside – avoid putting stress on the 3-wire
ribbon cable, which is soldered to the Contact Board.
13. If the Ratio Beam is to be removed, unsolder the 3-wire ribbon cable from
the Contact Board. (See Figure 3-25.) Wires glued to post
on Ratio Beam
Contact
Board
glued to
frame
Figure 3-25. Contact Board with ribbon cable. Figure 3-26. Fine wires connected to the
Contact Board, and affixed to Ratio Beam.
14. Carefully pry the Contact Board off
the Load Cell frame, and tape it to
the Beam. Take care not to
stress or break the fine wires
connected to the Contact Board.
If they are broken, the Ratio Beam
must be replaced.
Note: The fine wires are glued to Figure 3-27. Contact Board taped to Ratio
a post on the Ratio Beam. (See Beam after removal from frame.
Figure 3-27.) This same glue
provides insulation. If the wires are disconnected from the Ratio Beam, the
insulation may be damaged, causing a short circuit. If this happens, the Ratio Beam
must be replaced.

15. Remove the Service Fixture,

releasing the Hanger.
(See Figure 3-28.)
Figure 3-28. Hanger.
16. Remove the two screws from the Magnet Half. (See Figure 3-29.) Pull the Magnet
Half away from the Ratio Coil. (Pull hard to overcome magnetic force and any
possible corrosion.)
17. Remove the screws in the Sideways Motion Stop Plate, Hole in vane must
and lift it off. (See Figure 3-30.) be clear.
Figure 3-29. Two screws secure Magnet Half. Figure 3-30. Sideways Motion
Stop Plate.

18. Note the position of the opening and then turn the black Up/Down Stop Screw, so the
Ratio Beam can clear the stop, and gently lift out the Ratio Beam.
Figure 3-31. Ratio Beam clearing stop on Figure 3-32. Magnets must be clean.
Up/Down Stop Screw as it is lifted out.
The Load Cell is now completely disassembled.
To reassemble the Load Cell, see Section 3.3.11, Load Cell Reassembly – Precision Balances.

3.3.9 Position Sensor Board Removal/Replacement/Adjustment – Precision
If the Position Sensor Board is defective and requires replacement, proceed as follows:
1. Open the balance, and remove the Load Cell.
2. Un-solder the wires that attach to
the Position Sensor Board. The 3-
wire Ribbon Cable is connected to
the Contact Board. The two white
wires at the top are thermistor
wires: polarity is not important. The
two wires at the bottom-right must
be placed back in their original 3-wire Ribbon
position. (See Figure 3-33.) Cable
Thermistor cables
White, Red
Figure 3-33. Position Sensor Board.

3. Remove the three screws holding the Position Sensor Board in place.
(The two on the right have washers. The one on the left doesn’t.)
4. Remove the Position Sensor Board, and install the replacement. Insert all screws
previously removed. Tighten the screws finger-tight to allow adjustment in Step 9.
5. Re-solder all wires. (See Figure 3-33.)
6. Place the Load Cell in position and mount it with one screw.
7. Connect the cable from the Main PCB to the Position Sensor Board.
8. Operate the balance with the Weighing Pan in its normal position, but with the top
cover off. Power on using the middle button on the PCB.
NOTE:
The Position Sensor Board contains an Optical Sensor which must be positioned in
the Ratio Beam’s center of travel for the balance to function properly.
9. Adjust the vertical position of the

Position Sensor Board: if it is too
high or too low, the display
indicates Error 8.X.
(See Figure 3-34.) Move it until the
display indicates other than 8.X.
10. Tighten the screws on the Position
Sensor Board. (See Figure 3-35.)
11. Insert and tighten the two Figure 3-34. Adjust position of Sensor Board
remaining screws to secure the until Err8.X does not appear.
Load Cell. Check again that an
Error 8.X is not displayed. Note: A 2.5mm Allen Key can be cut to fit the
space between the Housing and the Position
Sensor Board.

3.3.9 Position Sensor PC Board Removal/Replacement/Adjustment – Precision
12. After completing the adjustment, turn the balance off and remove the Pan and Pan
Support.
Mounting
Mounting Screws
Screw
Figure 3-35. Position Sensor Board.
13. If a new Position Sensor Board has been installed, see Appendix C and follow the
instructions to restore the EEPROM.
3.3.10 Main Printed Circuit Board (PCB) Replacement – All Balances
If the Display persistently shows Error 1 (invalid checksum data) or 2 (overload or underload
condition), and normal remedies fail to solve the problem, the PCB may need to be replaced.
1. Disconnect the Load Cell Cable, RS232 Cable, and Power Cable.
2. Remove the screws on the Main PC Board which secure it to the Base.
3. Install replacement Main PC Board in the reverse order as removed. Check the LCD
display on the new board and remove the protective plastic covering if in place.
4. Reassemble the balance.
5. Complete the PCB installation using the Pioneer Software Service Tool – see
Appendix C.3, Install New Main Printed Circuit Board.
6. After assembly, verify that the balance meets all specifications. (See Chapter 1.)
Perform all tests. (See Chapter 4.)

3.3.11 Load Cell Reassembly – Precision Balances

Before re-assembly, take the following maintenance steps:
– Be sure all Flexures are straight, or replace them with new ones.
Place each Flexure on a clean flat surface and check that both sides rest evenly on the
surface. If a Flexure is bent even slightly, it must be replaced. (See Figure 3-23.)
– Be sure all parts are clean and free of debris.
1. Adjust the black Up/Down Stop

Screw so the Ratio Beam can
clear.
2. Insert the Ratio Beam into the
Load Cell frame. (See Figure 3-
36.)
3. Install the Service Fixture and
Hanger to the frame and the Ratio
Beam. Hold the Hanger by hand Figure 3-36. Installing Ratio Beam,
while inserting the two screws that clearing the Up/Down Stop Screw.
secure the Fixture to the Hanger.
Then insert the four screws that
secure the Fixture to the
Load Cell frame and the Ratio Beam. (See Figures 3-38 and 3-39.)
Screws connecting Service Fixture to Screws connecting Service Fixture to
Ratio Beam and Load Cell frame Ratio Beam and Load Cell frame
Screws
holding
Service
Fixture to Screws connecting
Hanger Service Fixture to Hanger
Figure 3-37. Service Fixture for 150g to Figure 3-38. Service Fixture for 510g to 4100g
410g Precision Load Cell, attached to Precision Load Cell, attached to Hanger, Ratio
Hanger, Ratio Beam, and Load Cell frame. Beam, and Load Cell frame.
4. Adjust the Up/Down Stop Screw so the groove is half way above and below the
stop tab. (Close it completely, then open it completely counting the turns, then
close it half-way.)

3.3.11 Load Cell Reassembly – Precision Balances.
Figure 3-39. Sideways Motion Figure 3-40. Two screws secure Magnet Half.
Stop Plate.
5. Position the Sideways Motion 6. Position the Temperature Sensor

Stop Plate so the small post in wires so they clear the opening on the
the Ratio Beam is centered in bottom of the Magnet Half. (See
the hole in the Stop Plate. Then Figure 3-40.) Install the Magnet Half in
insert and tighten the two screws front of the Ratio Coil, so screw holes
and washers. (See Figure 3-39.) align. Insert the two screws and
tighten them.
7. Carefully remove the tape from the

Contact Board (see Step 13, page
3-11) and re-position the Contact
Board on the Load Cell frame. Be
extremely careful not to stress or
break the fine wires attached to the
Contact Board.
8. Glue the Contact Board to the Figure 3-41. Contact Board.

frame, as in Figure 3-41.
9. Attach the Position Sensor Board to the Load Cell frame, using three screws. (See
Figure 3-35.) The left side screw goes in the outside hole. It has no washer. The
two right-side screws both have washers. Install screws finger-tight, so the board
can be moved for adjustment, in Step 17 below.
10. Solder the 3-wire Ribbon Cable to the Contact Board. (See Figure 3-41.)
11. Solder the two small wires to the solder points on the bottom
of the Position Sensor Board, and the two on the top. The two
on the bottom must be re-soldered in the same positions as
pictured in Figure 3-42: white on left, red on right. The two
wires on the top connect to the Temperature Sensor. Their
order is not important.
Figure 3-42. Solder
points on Position
Sensor Board.


12. Install the Bottom and Top Flexure Arms, in that order, Flexure side down. (See
Figures 3-43 and 3-44.) Avoid bending the Flexures. If bent, they must be replaced.
Screws
securing
Flexure
Arms
Figure 3-43. Precision Load Cell top. Figure 3-44. Precision Load Cell bottom.
13. Install the Vertical Flexure, Ratio Beam Vertical Ratio Beam
with the elongated hole down. Flexure Flexure Flexure
(See Figure 3-45.)
14. Install the two Ratio Beam
Flexures, with the elongated holes
down.
15. Remove the Service Fixture.
Figure 3-45. Ratio Beam Flexures and

Vertical Flexure.
16. Position the Load Cell in the

balance Housing. (See Figure
3-46.) Insert and tighten the three
screws. Be sure the Load Cell is
squarely mounted in the Housing.
Connect the cable from the Main
PCB to the Position Sensor Board.
Cable from Main

PCB to Position
Sensor Board
Figure 3-46. Insert the 3 screws to secure
Precision Load Cell in Bottom Housing.


17. Adjust the Position Sensor Board: follow steps 9 through 11 in Section 3.3.9
(summarized here). With the Weighing Pan in its normal position but the Housing
off, power on the balance. The On/Off switch is the middle button on the main PCB.
NOTE:
18. Adjust the vertical position of

the Position Sensor Board: if it
is too high or too low, the
display indicates Error 8.X.
Move it until the display
indicates other than 8.X.
Then tighten the screws on
the board. (See Figure 3-47.)
19. When adjustments are

complete, tighten the screws,
carefully checking that the
display does not show an
error 8.X. (If it does, repeat Figure 3-47. When Position Sensor Board shows
Step 18.) normal weight, tighten its screws with an Allen Key.
20. Install the Load Cell Cover.
21. Perform Off-Center Load Adjustments. (See Chapter 4.)
22. Test the balance. (See Chapter 4.)

3.3.12 Removing the InCal Mechanism from InCal Analytical Balances

This section explains the steps for disassembly, servicing and reassembling the Analytical
balances with the InCal mechanism.
Figure 3-48 shows the balance with the Top Cover and Load Cell Cover removed.
Screws in InCal Weight Cover
InCal
Motor
Screws in InCal Weight Cover

Figure 3-48. Analytical Balance with InCal Mechanism.
3.3.13 Removing Internal Calibration Weights and Components
Follow these steps to remove the InCal Weight Covers and Weights:
1. Remove the screws that
hold Weight Covers on
both sides of Load Cell.
(See Figure 3-48.)
2. Lift off the Weight Covers,

and then lift out each of
the Weights.
InCal
Weights
Figure 3-49. InCal Weight Covers removed.

3.3.13 Removing Internal Calibration Weights and Components

3. Remove the Load Cell.

that secure the Weight
Lifter to the base. See
Figure 3-50.)
5. Take out the Weight

Lifters.
6. Remove the screws that Screws holding
secure the InCal Motor Weight Lifters
Assembly to the base.
7. Lift out the InCal Motor
Figure 3-50. Bottom Housing with Load Cell,
Assembly from the base.
Weight Arms and Weights removed.
Carefully free the InCal
Motor's ribbon cable from the groove in the base.
8. Remove the screws and washers

that secure the InCal Motor to the
assembly.
9. Note the position of the InCal Motor

Cam as it is removed. Be sure the
Cam is in the same position when
the mechanism is reassembled.
See Figure 3-52.)
Figure 3-51. InCal Motor removed

from its assembly.
Figure 3-52. InCal Motor Cam in

correct position for reassembly.
Before reinstalling the InCal mechanism, be sure all of its components are clean and free of
debris. If the InCal Motor or its Cam is defective, it must be replaced.

3.3.14 Reinstalling Internal Calibration Components

When reinstalling the Internal Calibration Components, follow these steps:
1. Insert the InCal Motor’s Cam in the hole of the InCal Motor Assembly (see Figure
3-51), insert the four screws that hold the motor to the frame and tighten them.
2. Mount the InCal Motor Assembly in the Bottom Housing. (See Figure 3-50.)
3. Before inserting the screws, carefully place the motor’s ribbon cable in the groove in
the Housing, and thread it beside the RS232 cable along the outside of the Housing.
Insert its plug in the PCB.
4. Insert and tighten the screws that hold the assembly to the Housing.
5. Position the Weight Lifter as in Figure 3-50, insert and tighten the screws holding it to
the Housing.
6. Install the Load Cell in the Housing, carefully place the InCal Weights in the Weight
Holders, position the Weight covers above them, insert and tighten the screws.
7. Test the InCal mechanism: see Appendix C, Section C.5.1, Incal Weight Mechanism
Testing.
3.3.15 Load Cell Removal/Installation – Analytical Balances
8. Disassemble the Housing and open

the balance. (See Section 3.2.1.)
9. Carefully unplug the cable that

connects the Main PCB to the
Position Sensor Board. (See
Figure 3-53.)
9. Remove the three screws holding Figure 3-53. Cable connects to

the Load Cell in place – in the the Position Sensor Board.
middle of the Bottom Housing.
(See Figure 3-54.)
10. Carefully lift the Load Cell out of the

base.
11. To re-install the Load Cell, follow

Steps 1 through 4 in reverse.
It is now possible to disassemble the Load Cell

for cleaning, alignment, or replacing parts.
Figure 3-54. On Analytical balances, the 3

screws securing Load Cell are on bottom.
Pioneer Balances Service Manual 3-21 Ohaus Corporation www.ohaus.com

3.3.16 Disassembling Analytical Load Cells
The following steps require the Service Fixtures for the Load Cell you will be disassembling.
Note:
Do not attempt repairs without the correct fixture.
The Service Fixture for the Analytical balances includes two shims. (See Figure 3-55.)
Figure 3-55. Service Fixture, screws and shims for Analytical balances.
1. Remove the three screws and washers from the Mounting Plate, and lift it off.
Set aside two of the screws to use in the next step. (See Figure 3-56.)
Loosen these Loosen these

screws. screws.
Screws on
Bottom Mounting
Plate
Figure 3-56. Bottom Mounting Plate and Figure 3-57. Top Mounting Plate and Flexure
Flexure Arms, Analytical balance’s Load Cell. Arms, Analytical balance’s Load Cell.
2. Loosen the screws that secure the Flexure Arms to the Load Cell (not the Hanger).
Ohaus Corporation www.ohaus.com 3-22 Pioneer Balance Service Manual

3. To protect the Flexures, secure the Hanger to the Load Cell with two screws and the
shims supplied with the Service Fixture. Use two screws that were removed from the
Bottom Mounting Plate earlier. Insert them finger-tight in the holes of the Hanger.
(See Figure 3-58.)
4. Insert the shims (from the Service Kit) between the Hanger and the Load Cell on the
right and left of the Hanger. (See Figure 3-59.) Keep the screws finger-tight while
inserting the shims, to avoid risk of damaging the Flexures.
Lock Plate protecting Shims

Vertical Flexure
Screws
inserted in Hanger to secure it
Figure 3-58. Screws removed from
Bottom Mounting Plate inserted
finger-tight into the Hanger. Figure 3-59. Shims are inserted between
the Hanger and the Load Cell on the left
and right of the Hanger.
5. Tighten the two screws that Adjustment screws

stabilize the Hanger. (Don’t touch.)
6. Remove the two screws and

washers that secure the Top
Bracket, and lift it off.
(See Figure 3-60.)
NOTE:
Do not touch the two rear-most screws
with nuts on top. These are adjustment Top Bracket
screws.
Figure 3-60. Analytical balance Load Cell

with Top Bracket visible.
7. Remove the Vertical Flexure, which is located in the center of the Hanger. Loosen
the two screws that secure the Vertical Flexure to the Hanger. Carefully remove the
Lock Plate, washers and bushings, keeping track of their order (for later reassembly),
as illustrated in Figure 3-61.
Note: Be sure to lay the Flexure on a flat surface, to avoid bending it.

Top Screw
Top Bushing
Elongated hole Lock Plate

on bottom Bottom Screw
Figure 3-61. Vertical Flexure and screws,

Lock Plate, washers, and bushings, removed
from center of Hanger. Note the different-sized
screws and bushings for top and bottom.
Also note the elongated hole on the bottom
side of the Vertical Flexure.
8. Carefully loosen and remove the four screws that secure the Top Flexure Arm to the
Load Cell, and remove the Top Flexure Arm. (See Figure 3-62.) Place the Flexure
Arm on a flat surface. Note that the Flexure screws on the Analytical balances have
two washers each: a thicker silver-colored one on the bottom, and a smaller black
one on top.
Bottom Flexure Arm

Top Flexure Arm
Figure 3-62. Top Flexure Arm (Analytical). Figure 3-63. Bottom Flexure Arm (Analytical).
9. Turn the Load Cell over and remove the four screws that secure the Bottom Flexure
Arm to the Load Cell, and remove the Bottom Flexure Arm. (See Figure 3-63.)
Place it on a flat surface.
NOTE:
When handling the Flexure Arms, be careful not to bend the Flexures.
10. Carefully examine each Flexure to see if it is bent. If uncertain, place the Flexure on
a clean flat surface and check that both sides rest evenly on the surface. If a Flexure
is bent even slightly, it must be replaced for the balance to operate properly.

11. Remove the Hanger from the Load Cell by removing the two screws inserted earlier.
(See Figure 3-64.)
Ratio Beam Flexures

Figure 3-64. Hanger with two screws.
Figure 3-65. Service Fixture attached to the

front of Load Cell after removing Hanger.
12. Install the Service Fixture, using the finger screws provided, in order to stabilize the
moving parts. (See Figure 3-65.)
13. Remove the Ratio Beam Flexures.
14. Carefully examine each Flexure to see if it is bent. If uncertain, place the Flexure on
a clean flat surface and check that both sides rest evenly on the surface. If a Flexure
is bent even slightly, it must be replaced for the balance to operate properly.
15. Remove the two screws that secure the Vane as shown in Figure 3-66.
Then lift the Vane out and set it aside.
Figure 3-67. The Vane removed.
Figure 3-66. The Vane is secured by two

screws.

16. Unsolder the two white wires connected to the Position Sensor Board. Then remove
the two inset screws that secure the board to the Load Cell. Carefully lift the Position
Sensor Board away from the Load Cell. (See Figure 3-68.)
Figure 3-68. Two solder points and two screw

holes for removing the Position Sensor Board.
Contact
Board with
3-wire
cable
attached
Figure 3-69. Contact Board with 3-wire ribbon
cable soldered to it.
17. Unsolder the three points of the 3-wire ribbon cable that connect to the Contact
Board at the rear of the Load Cell. (See Figure 3-69.)
18. Use an ohm meter to measure resistance from the middle wire to each side wire.
The readings should be approximately equal, at around 400-460 Ω (ohms). The
resistance from any wire to the frame should be open or infinity. If any resistance is
measured, the Ratio Beam must be replaced.
19. Remove the four screws that secure the Magnet Half. (See Figure 3-70.) Grasp the
Magnet Half from the top, and lift it out. It may be necessary to pull hard, to
overcome the magnetic force, as well as possible resistance caused by corrosion.
Figure 3-70. Four screws secure the Magnet Figure 3-71. The Magnet Half, when
Half to the Ratio Beam. removed, should be cleaned.

NOTE:
Use extreme caution in moving the Contact Board to avoid stressing or breaking the
fine wires underneath it. (If one of these wires is broken, it must be replaced.)
20. Remove the screw in the Contact Board that had the 3-wire Ribbon Cable soldered
to it. Move the Board with great care, to protect the extremely delicate, fine wires
connected to it from underneath. (See Figure 3-72.)
21. Use a smaller screw to temporarily fasten the Contact Board to the screw hole on the
top of the Ratio Beam, as shown in Figure 3-73.
Figure 3-73. Use a small screw to fasten the

Contact Board to the Ratio Beam.
Screw hole to
fasten Contact
Board to Ratio
Beam
Figure 3-72. A screw connects the Contact

Board to the Load Cell.
22. Remove the Sideways Motion Stop

Plate on the top of the Load Cell,
which stabilizes the Ratio Beam. If
necessary, turn the black Up/Down
Stop Screw to allow the Ratio
Beam to clear. (See Figure 3-74.)
23. Remove the Service Fixture and

gently lift out the Ratio Beam.
Up/down Stop
Screw Screws holding
Sideways Motion Figure 3-74. Two screws hold the Sideways
Stop Plate Motion Stop Plate on top of the Load Cell.
The black Up/Down Stop screw holds the
Ratio Beam in place.
The Load Cell is now completely disassembled.
To reassemble the Load Cell, see Section 3.3.17, Reassembling Analytical Load Cells.

3.3.17 Position Sensor PC Board Removal/Replacement/Adjustment - Analytical
When the Position Sensor PC Board is defective and requires replacement, proceed as follows:
1. Open the balance, and remove the Thermistor wires

Load Cell. are soldered on
3-wire Ribbon Cable Inset Screws the bottom
2. Un-solder the thermistor wires
and ribbon cable. (See Figure
3-75.)
3. Remove the two inset screws
holding the Position Sensor
Board in place.
4. Remove the Position Sensor
Board, and install the
Figure 3-75. Position Sensor Board
replacement. Insert the
(Analytical).
screws previously removed.
Tighten the screws finger-tight to allow adjustment in Step 9.
5. Re-solder the wires. (See Figure 3-75.)
6. Place the Load Cell in position and insert the screws finger-tight, to facilitate Step 9.
7. Connect the cable from the Main PCB to the Position Sensor Board.
8. Operate the balance with the Weighing Pan in its normal position, but with the Top
Housing off. Power on using the middle button on the PCB.
NOTE:
9. Adjust the vertical position of the

Position Sensor Board: if it is too high
or too low, the display indicates Error
8.X. (See Figure 3-76.) Move the
board until the display indicates other
than 8.X.
10. Tighten the screws on the Position
Sensor Board. (See Figure 3-76.)
Figure 3-76. Adjust Position Sensor Board
11. Insert and tighten the two remaining
vertically until Err8.X does not appear.
screws to secure the Load Cell.
Check again that an Error 8.X is not
displayed. (If so, repeat Step 9.)
12. Disconnect the power. Install the
Load Cell Cover and close the
balance.

3.3.18 Reassembling Analytical Load Cells

Before reassembly, take the following maintenance steps:
• Be sure all Flexures are straight, or replace them with new ones.
• Be sure the hole in the Vane is clear and that the Vane is free of debris.
• Be sure the Magnet is clean and free of debris.
Reassemble the Load Cell by following these steps:

1. Carefully insert the Ratio Beam into the Load Cell frame. Adjust the black Up/down
Stop Screw so the Ratio Beam can clear. (See Figure 3-77.)
Figure 3-77. Ratio Beam needs to clear the Figure 3-78. Service Fixture is installed prior
groove in the Up/Down Stop Screw. to installing Ratio Beam Flexures.
2. Install the Service Fixture.
3. Adjust the Up/down Stop Screw
so the groove is half way above
and below the stop tab. (Close it
completely, then open it
completely, counting turns, then
close it half-way.)
4. Position the Sideways Motion
Stop Plate so the small post in the
Ratio Beam is centered in the Figure 3-79. Sideways Motion Stop Plate and
hole in the Plate. Then insert and Up/Down Stop Screw.
tighten the two screws
(See Figure 3-78.) Screw holding Contact Board
5. Install the Ratio Beam Flexures, with

elongated hole down. Each screw
has two washers: a silver-colored one
near the Flexure, a black one near
the screw.
6. Move the Contact Board from the Figure 3-80. Elongated holes on Ratio
Ratio Beam to the Load Cell frame. Beam Flexures go on the bottom.
Avoid breaking the fine wires!

7. Carefully insert the Magnet Half in

front of the Ratio Coil. Align the
screw holes on its four corners. Then
insert and tighten the four screws.
(See Figure 3-81.)
Figure 3-81. Installing the Magnet Half.
Figure 3-82. Four screws on Magnet Half.

8. Install the Position Sensor Board,
leaving the screws finger-tight.
(Tip: Position each screw before
installing the board; stand the Load
Cell on the Service Fixture, and lower
the PSB into position with an Allen
Key holding one screw – See Figure
3-83.) Solder points
for white wires Figure 3-83. Position Sensor Board.
9. Solder the two wires from the

Temperature Sensor to the two solder
points on the Position Sensor Board.
(See Figure 3-83.) It’s not critical
which wires goes to which solder
point.
10. Solder the 3-wire Ribbon Cable to the Figure 3-84. 3-wire cable soldered to
Contact Board. (See Figure 3-84.) Contact Board.
11. Install the Vane. Make sure the post

is centered and that the Vane is not
rubbing. (See Figure 3-85.)
12. Remove the Service Fixture.
Figure 3-85. Installing the Vane.

13. Install the Hanger: insert two screws loosely. Distance shown by arrows should be
8mm. Insert shims on each side and tighten screws. (See Figures 3-86 and 3-87.)
Figure 3-86. Screws from Bottom Mounting Figure 3-87. Insert shims between the Hanger
Plate inserted finger-tight into the Hanger. and the Load Cell on both sides.
Figure 3-88. Bottom Flexure Arm. Figure 3-89. Top Flexure Arm.
14. Install the Bottom Flexure Arm, screw-side down. Each screw has two
washers: a silver-colored one near the Flexure, a black one near the
screw. (See Figure 3-88.)
15. Install the Top Flexure Arm, screw-side down. (See Figure 3-89.)
16. Install the Vertical Flexure, bottom screw last. Figure 90. Vertical Flexure.
Note the order of parts, as shown in Figure 3-91.
Top Screw
Top Bushing
Elongated hole Lock Plate

on bottom Bottom Screw
Figure 3-91. Vertical Flexure and screws, Lock Plate,

washers, and bushings. Note the different-sized
screws and bushings for top and bottom. Also note the
elongated hole on the bottom side of the Vertical Flexure.

17. Install the top bracket. (See Figures 3-92 and 3-93.)
Top Bracket (with Top Bracket

InCal Weight Arms)
Figure 3-92. Analytical InCal Load Cell Figure 3-93. Analytical balance Load Cell
with Top Bracket visible. with Top Bracket visible.
18. Remove the screws and shims

from the Hanger.
19. Install the Bottom Mounting Plate
as shown. Note the position of the
Weigh Below Hook. (See Figure
3-94.)
Screws on
Bottom Mounting
Figure 3-94. Bottom Mounting Plate on
Plate
Analytical Load Cell.
20. Position the Load Cell in the

balance Housing. Insert and
tighten the three screws, from
underneath the Bottom Housing.
Be sure the Load Cell is squarely
mounted in the Housing. Connect
the cable from the Main PCB to the
Position Sensor Board. (See
Figure 3-95.)
Cable from Main

PCB to Position
Sensor Board
Figure 3-95. Ribbon cable connects PSB to

Main PCB.

NOTE:
21. Adjust the Position Sensor Board: power on the balance with the Top Housing off but
the Weighing Pan in its normal position. The On/Off switch is the second button
from the right on the main PCB.
22. Adjust the vertical position of

the Position Sensor Board: if it
is too high or too low, the
display indicates Error 8.X.
Move it until the display
indicates other than 8.X.
Then tighten the screws on
the board. (See Figure 3-96.)
Figure 3-96. When Position Sensor Board shows
23. Install the Load Cell Cover. normal weight, tighten its screws with an Allen Key.
24. Perform Off-Center Load Adjustments. (See Chapter 4.)
25. Test the balance. (See Chapter 4.)

3.3.19 Block Style Load Cell Disassembly & Replacement
Typical Block Style Load Cells with InCal Mechanisms installed are shown in Figure 3-97.
The Load Cell illustration may vary from actual Load Cells. Major components are shown.
InCal Weight InCal Motor Cable Connector
Aluminum Sleeves
Ratio Beam
Base Plate
InCal Mechanism Up/Down Stop Screw InCal Weight Arm
Load Cell PCB Cone InCal Weight
Position Sensor
Assembly
InCal Motor
Shield
InCal Motor
Ratio Beam
Figure 3-97. Block Style Load Cells: Precision (above) and Analytical (below).
Block style Load Cells are repairable. However, if serious damage has occurred, it may be
necessary to replace the Load Cell.
Load Cell Kits are available for replacement purposes for all Block Style model balances. Each
kit is assembled and consists of metal base plate, a Load Cell, the InCal Weight Assembly
mounted to the base plate, and a package of labels. Check the label on the balance and verify
the capacity and model before ordering a new Load Cell kit.
Note: Analytical and Precision Block Style Load Cells are different, but the service procedures
are the same.

3.3.20 Block Style Load Cell Removal & Replacement with Load Cell kit
Use the following procedure to replace a Block Style Load Cell using a Load Cell kit.
1. Remove the Top Housing. (See Section 3.2.1.)
2. Remove the Load Cell Shield by grasping the sides and pulling upwards.
3. Remove the four screws and washers that secure Load Cell to the Bottom Housing.
Remove the Load Cell.
4. Disconnect the cable(s).
5. Install the replacement Load Cell using the four screws previously removed and
connect the flexible cables.
6. Replace the Load Cell Shield over the Load Cell. Press it firmly into place.
7. Reassemble the balance.
8. Follow the instructions in Appendix C for installing the Load Cell.

9. Re-calibrate the balance following instructions in Appendix B, Service Calibration.
10. Re-calibrate the balance following instructions in Appendix A, Standard Calibration.
11. Check the performance of the balance using tests in Chapter 4.
3.3.21 Progressive Disassembly of Block Style Load Cells

Use the following procedures for progressive disassembly of Block Style Load Cells. When the
defective part is reached, replace it as described. But note that the procedures are not meant to
be stand-alone – you must complete each step.
The following steps require the Block Style

Service Toolset. (See Figure 3-98.)
CAUTION:
Exercise extreme care not to twist or
deform the Load Cell in any way. Do
not drop or hit the Load Cell. Serious
damage to the Load Cell can make it
necessary to replace the Load Cell.
Figure 3-98. Service Toolset for Block Style

Load Cells. PN 476000-030.

3.3.22 Internal Calibration Testing
This section describes how to test the internal calibration in a Block Style Load Cell. There can
be several reasons that internal calibration does not function, including a broken or jammed
InCal Mechanism, a defective InCal Motor, or a defective Main PC Board. To test the internal
calibration, proceed as follows:
1. Connect an RS232 cable and a computer to the balance.
2. Follow instructions in Appendix C, Section C.5.1, Incal Weight Mechanism Testing.
3. Observe the motion of the InCal Weight when you press Raise or Lower.
If the weight does not move, replace the InCal Motor. (See Section 3.3.21.)
4. If the operation is not smooth, replace the entire InCal Mechanism. (See Section
3.3.22.)
3.3.23 InCal Motor Removal & Replacement

1. Remove the balance’s Housing and Load Cell, as described in earlier sections.
2. Remove the two screws holding the InCal Motor and InCal Motor Shield in place
from the InCal Mechanism. (See Figures 3-99 and 3-100.)
InCal
Mechanism
InCal Motor
InCal Motor
Shield
Mounting
Screws holding Screws
InCal Motor
Figure 3-99. InCal Motor. Figure 3-100. InCal Motor Removal.
3. With the Incal Weight in upper-most

InCal Weight
position, the Motor Coupler should
be in the position shown in
Figure 3-101. Motor
Coupler
Figure 3-101. Motor Coupler.

3.3.23 InCal Motor Removal & Replacement
4. Install the Coupler supplied with the

replacement motor, then rotate the Correct Angle
Motor Shaft by hand until it is in a
counter-clockwise position. (See
Figure 3-102.) If the Coupler is not in
the position shown, remove the
screw and coupler, reposition as
shown, and tighten the screw on the
Motor Shaft.
Screw Coupler
Figure 3-102. Motor Shaft in counter-

clockwise position.
5. Install the InCal Motor to the InCal Mechanism. The Motor Shaft must be in the
position shown in Figure 3-102.
6. Secure the InCal Motor and InCal Motor Shield to the InCal Mechanism with the
screws previously removed.
7. Test the InCal Mechanism again, as described in Section 3.3.21.
8. If the test is successful, re-install the Load Cell. (See Section 3.3.19.)
3.3.24 InCal Mechanism Removal
NOTE: Replacement InCal Mechanisms are available assembled with the InCal Motor installed.
1. Open the balance and remove the Load Cell as described earlier.
2. Remove the three Mounting Screws from the InCal Mechanism. (See Figure 3-103.)
Figure 3-104. Removing the InCal

3 Mounting Screws
Mechanism.
Figure 3-103. Mounting Screws holding InCal

Mechanism.
3. Slide the InCal Mechanism as shown to remove it. (See Figure 3-104.)

3.3.25 InCal Mechanism Installation

1. Rotate the InCal Motor shaft until the Weight is in the top position.
2. Slide the new InCal Mechanism into position. Fasten it with the three screws
previously removed, but do not fully tighten them yet.
3. Position the InCal Mechanism so the spacing between the InCal Weight and the
InCal Weight Arms is even on both sides. (See Figure 3-105.)
Equal
Spacing
Adjust Spacing
Figure 3-105. InCal Mechanism Alignment. Figure 3-106. Centering InCal Weight.
4. Make sure the InCal Weight is lined up properly on the InCal Weight Arm. It must be
centered in the slots of the Weight Arm. (See Figure 3-106.) When the Weight
Mechanism is properly aligned, tighten the three screws and re-check alignment.
5. Test the InCal Mechanism with software. (See Section 3.3.21.

3.3.26 Position Sensor Assembly Removal/Installation on Block Style Load Cell
Position Sensor Removal:

1. Remove the three screws of the Position Sensor Assembly.
2. Raise the Position Sensor Assembly, which is held by the magnetic field.
3. If the Position Sensor Assembly has to be changed, unsolder the Flexible Ribbon
Cable. (See Figure 3-107.)
Unsolder 6 Contacts
3 Screws
Figure 3-107. Removing Position Sensor.
Position Sensor Installation:

1. Mount the Position Sensor Assembly. Align it centrally on the Ratio Beam Pin,
and fasten it with the three screws. (See Figure 3-107.)
Note:
The flange of the Position Sensor Assembly is pre-bent to ensure its precise
positioning after screwing it on. Do not attempt to bend it straight!
Ratio Beam Pin
Sensor Assembly
Hole
Figure 3-108. Ratio Beam Pin Alignment.

2. Solder the Flexible Ribbon Cable to the six contacts shown in Figure 3-108.
3. Adjust the Up/Down Stop following procedures in Section 3.3.31.

3.3.27 Removing the Block Style Load Cell from the Base Plate
This procedure is necessary before proceeding with other repairs to the Load Cell.
Base Plate Removal
1. Remove the Weigh Below Hook and Screw. (See Figure 3-109.)
Mounting Screws Weigh Below Hook & Screw
Figure 3-109. Base Plate Removal.
2. Hold the Block Style Load Cell and remove the two Load Cell Mounting Screws.
(See Figure 3-109.)
Note: At this point, other repairs may be made to the Load Cell.

3.3.28 Installing the Block Style Load Cell on the Base Plate
Block Style
Load Cell
Mating
Surfaces
Base Plate
Mounting
Weigh Below Hook & Screw
Screws
Figure 3-110. Load Cell Mounting Components.
Base Plate Installation

1. Make sure the mating surfaces on the Base plate and the Load Cell are clean.
(See Figure 3-110.)
2. Position the Load Cell on the base and install the two mounting screws.
Do not tighten them fully.
3. Looking down at the top of the Load Cell, align it with the Base Plate.
(See Figure 3-111.)
4. Now carefully tighten the two mounting screws and re-check alignment.
Alignment Area
Figure 3-111. Load Cell Alignment to Base Plate.

5. Install the Weigh Below Hook and screw at the bottom of the Base Plate.
(See Figure 3-110.)

3.3.29 Removal and Installation of the Block Style Load Cell PC Board
1. Remove the Load Cell from the Mounting Plate.
(See previous section.)
2. Unsolder the Temperature Sensor Board wires.
(See Figure 3-112.)
3. Unsolder the Position Sensor Assembly from the Block Style Load Cell PC Board.
Unsolder Position Sensor

Assembly
Load Cell Load Cell Unsolder Temperature

Ratio Beam Cable Board Screw PC Board Sensor Wires
Figure 3-112. Block Style Load Cell PC Board Item Locations.
4. Disconnect the Ratio Beam cable. (See Figure 3-112.)
5. Remove the Load Cell Board Screw and change the Board. (See Figure 3-112.)
6. Install new board, ensuring the slot in the board is inserted in the slot in the Load Cell
Frame. (See Figure 3-113.)
CAUTION:
When screwing in, first turn the self-tapping Cell Board Screw in a counterclockwise
direction until the first screw thread engages and then tighten it. (See Figure 3-111.)
7. Re-solder the Temperature Sensor Board and the Position Sensor Assembly.
8. Follow instructions in Appendix C to Restore the EEPROM.
Slot
Mounting Screw
Figure 3-113. Block Style Load Cell PC Board Removed from Load Cell.

3.3.30 Removing the Load Cell PCB-Temperature Sensor-Position Sensor Assembly

The Temperature Sensor, Position Sensor and the Load Cell PCB can be removed and installed
as an assembly, as follows:
Position Sensor
Load Cell PCB
Temperature
Sensor
Figure 3-114. Load Cell PCB-Temperature Sensor-Position Sensor assembly.
1. Remove the three screws that secure

the Position Sensor to the Magnet.
Lift it off, gently but firmly – to
overcome the magnetic resistance,
but avoid breaking the soldered
connections to the Load Cell PCB.
(See Figure 3-115.) Soldered
connections to
Note: Do not adjust the screws Load Cell
around the Temperature Sensor hole. PCB
It could ruin the Load Cell. Figure 3-115. Position Sensor.
2. Remove the screw on the bottom

edge of magnet that secures the
Temperature Sensor. It has a very
fine thermister extending into the
hole between the three screws on
Don’t adjust
the bottom of the Magnet. (See screws around
Figure 3-116.) Temperature
Sensor hole!
3. Lift out the Temperature Sensor,
careful to avoid stressing the wires
connecting it to the Load Cell PCB.
Figure 3-116. Removing Temperature Sensor.

Don’t adjust
screws around
Temperature
Sensor hole!

3.3.30 Removing the Load Cell PCB-Temperature Sensor-Position Sensor Assembly

4. Remove the ribbon cable
connecting the Load Cell PCB to
the Contact Board.
5. Remove the screw securing the

Load Cell PCB to the Load Cell
frame. (See Figure 3-117.)
Do not to stress the transparent
Position Sensor cable or the wires
holding the Temperature Sensor. Figure 3-117. Load Cell PCB.
3.3.31 Removing the Ratio Beam on Block Style Load Cells

1. Remove the Position Sensor, PCB and Temperature Sensor (the three as an
assembly), prior to removing the Ratio Beam. (See previous section.)
If necessary, remove the
Contact Board Cover.
Note: If Contact Board has a
cover, as in Figure 3-118, the
cover holder remains after
cover is removed.
(See Figure 3-119.)
Figure 3-118. Contact Board Figure 3-119. Contact
Cover is removed by squeezing Board with cover holder.
the plastic post.
2. Insert the Centering

Pins from the Service
Toolset in the holes
provided. (See
Figure 3-120.)
Centering Pins
Figure 3-120. Centering pins.
Centering Pins Centering Pins
installed installed
Figure 3-121. Centering Pins Installed.

3. Hold the Contact Coil Hole in Ratio Beam

Board to ensure the Wires for Contact Board
fine coil wires cannot
tear off, then remove
the Fastening Screw
as shown in Figure
3-122.
Contact Board Fastening Screw

Figure 3-122. Contact Board Location.
4. Remove the Contact
Board from the Load
Cell frame; screw it on
to the hole in Ratio
Beam directly above it.
(See Figures 3-122
and 3-123.)
Note: The screw changes Figure 3-123. Contact Board with cover holder off.
from the lower to the
upper hole on the Contact Board before inserting it into the hole on the Ratio Beam.
5. Carefully loosen and remove the nuts on the Ratio Beam while holding the screw
heads to prevent movement. This is very important! (See Figure 3-124.)
Ratio Beam
Loosen Nut Hold Stationary
Figure 3-124. Loosening Ratio Beam Nuts. Figure 3-125. Ratio Beam Screws and
Washers removed.

Note: Not all Load Cells require a Weight Arm as shown. If the Load Cell does not
have this style Weight Arm, proceed to Step 9.
6. Remove the screws, washers and nuts holding the InCal Weight Arm.
(See Figure 3-126.)
InCal Weight Arm
Loosen Nut Hold Stationary
Figure 3-126. Loosening InCal Weight Arm Figure 3-127. Weight Arm Screws
nuts. and Washers removed.
7. Carefully slide the InCal Weight Arm as shown in Figure 3-128.

Figure 3-129 illustrates the InCal Weight Arm removed.
InCal Weight Arm
Figure 3-128. InCal Weight Arm Removal.
InCal Weight Arm
Figure 3-129. InCal Weight Arm removed.

8. Remove the aluminum sleeves. (See Figure 3-130.)
9. Note the position of the Up/Down

Stop Screw. Turn the Up/Down Stop Aluminum Sleeves Aluminum Sleeves
Screw so the Ratio Beam can be
removed. (See Figure 3-131.)
Figure 3-130. Aluminum Sleeves removed.
Centering Pins
Figure 3-131. Up/Down Stop Screw.
10. Remove the centering pins. Figure 3-132. Centering Pins removed.
(See Figure 3-132.)
11. Carefully lift out the Ratio Beam. (See Figures 3-135 and 3-136.)
Figure 3-135. Removing the Ratio Beam. Figure 3-136. Ratio Beam Removed.
12. Remove the Aluminum Sleeves.

(See Figure 3-137.)
This completes the disassembly.
Figure 3-137. Removing the Aluminum

Sleeves.

3.3.32 Installing the Ratio Beam on Block Style Load Cells
1. If a new Ratio Beam is being installed, remove the existing weights from the old
Ratio Beam and install them on the replacement Ratio Beam. (See Figure 3-138.)
Note: Some Load Cells require one Ratio Beam weight, some require two, and some
do not require Ratio Beam weights.
Ratio Beam
Weights
Figure 3-138. Ratio Beam Weight Removal.

2. Examine the Load Cell slotted areas to be sure all areas are clean and free of debris.
Hold the Load Cell up to the light to see into the slotted areas. If dust or dirt appears
in any slotted area, use pressurized clean air normally used for cameras and gently
blow out any dirt. Use extreme care. Critical area is shown in Figure 3-139.
CAUTION:
DO NOT USE COMPRESSED OR SHOP AIR AS CONTAMINANTS AND
MOISTURE ARE PRESENT WHICH MAY DAMAGE THE LOAD CELL.
Critical Area
Figure 3-139. Load Cell Critical Area.
3. Check and clean the Magnet area. To

clean it, use a small wooden stick with
double-sided tape to remove any debris.
(See Figure 3-140.)
Note: Do not remove the three screws

under the magnet that surround the
Temperature Sensor. (See Figure 3-116,
page 3-43.)
Figure 3-140. Magnet Area.

3.3.32 Installing the Ratio Beam on Block Style Load Cells

4. Re-install the four Aluminum
Sleeves for the Ratio Beam
and four for the InCal Weight Arm.
(See Figure 3-142.)
5. Inspect the slotted area on the
Ratio Beam. Clean it if necessary.
(See Figure 3-141.)
Weight Arm
Vane
Sleeves
Ratio Beam
Sleeves
Slotted Area
Figure 3-142. Four Ratio Beam sleeves are
Figure 3-141. Ratio Beam Vane Slotted Area. larger than the four Weight Arm sleeves.
6. Carefully place the Ratio Beam into position on the Load Cell. Do not install the
screws yet. (See Figures 3-143 and 3-144.)
Figure 3-143. Replacing the Ratio Beam. Figure 3-144. Positioning the Ratio Beam over
the magnet (right).
7. Insert a Centering Pin to hold the
Ratio Beam in position, as shown in
Figure 3-145.
The Centering Pin also helps to

avoid stressing the internal
flexures. If the internal flexures are
stressed in the process of
reassembly, the Load Cell may be
ruined, and would then need to be
replaced. Figure 3-145. Centering Pin goes into first
hole after upward bend in Ratio Beam.

3.3.32 Installing the InCal Weight Arm

Note: Not all block style Load Cells have a Weight Arm as shown. If the Load Cell does
not have this style Weight Arm, proceed to Step 7 and insert second Centering Pin.
1. Carefully slide the InCal Weight Arm into position. (See Figures 3-146 and 3-147.)
InCal Weight Arm InCal Weight Arm
Figure 3-146. InCal Weight Arm before insertion. Figure 3-147. Inserting InCal Weight Arm.
2. Be sure the notch at the end of the Weight Arm aligns with the pin (inserted in Step 7
on the previous page) through the Ratio Beam’s screw holes..
3. Gently lift the Ratio Beam and insert a second Centering Pin in the InCal Weight Arm
near the Magnet. (See Figure 3-148.)
Figure 3-148. Weight Arm must be lifted slightly to insert Centering Pin.
4. Do not use tools in this step.

Install the screws, washers and
nuts for the InCal Weight Arm.
Work gently, to avoid stressing the InCal Weight Arm
Load Cell’s internal flexures.
5. After installing the screws, washers
and nuts by hand, hold the screw
head with a screw driver while Tighten Nut Hold Screw
tightening the nuts for the InCal
Weight Arm. (See Figure 3-149.)
Figure 3-149. Proper method for tightening
nuts while holding screw head stationary.

3.3.32 Installing the InCal Weight Arm
6. Remove the pin securing the InCal

Centering Pins
Weight Arm at the Magnet end.
7. Insert the pin just removed into the
hole below the one holding the first
centering pin. (See Figure 3-150.)
8. Do not use tools in this step.
Install the screws, washers and nuts
for the Ratio Beam. Work gently, to Figure 3-150. Centering pins in Ratio Beam.
avoid stressing the Load Cell’s
internal flexures.
9. After installing the screws, washers
and nuts by hand, hold the screw
head with a screw driver while
tightening the nuts for the Ratio
Beam. (See Figure 3-151.)
Figure 3-151. Tightening Ratio Beam nuts.
10. Turn the Up/Down Stop Screw to its

original position. (See Figure 3-152.)
11. Remove the Centering Pins. They
should fall out easily.
Figure 3-152. Up/Down Stop Screw.
12. Move the contact board as shown

in Figure 3-153. Be very careful Temporary
Contact
not to break the wires on the board. Wires Screw
Note: The screw changes from Hole
the upper to the lower hole on the
Contact
Contact Board before inserting it Board Contact
into the hole on the Load Cell Board
frame. Screw
Figure 3-153. Repositioning the Contact

Board and Screw.

3.3.33 Installing the Load Cell PCB-Temperature Sensor-Position Sensor Assembly

The Temperature Sensor, Position Sensor and the Load Cell PCB can be installed as an
assembly, as follows:
Position Sensor
Load Cell PCB
Temperature
Sensor
Figure 3-154. Load Cell PCB, Temperature Sensor and Position Sensor.
1. Install the Load Cell PCB by

fitting the groove on the left of
the PCB into the tab on the Load
Cell frame. (See Figure 3-155.)
When screwing in, first turn the

self-tapping Cell Board Screw in
a counterclockwise direction
until the first screw thread
engages and then tighten it. Figure 3-155. Groove on left of PCB fits tab
(See Figure 3-111, page 3-42.) on Load Cell frame.
2. Gently hold PCB in position while inserting and tightening the screw that secures it.
3. Carefully position the

Temperature Sensor under the
Magnet, so the Temperature
Sensor (a very fine thermister
that extends from the board)
Don’t adjust
goes into the hole between the screws around
three screws on the bottom of Temperature
the Magnet. (See Figure 3-156.) Sensor hole!
Figure 3-156. Temperature Sensor
4. Insert the screw to secure the extends into a hole in the Magnet
Temperature Sensor Board.
Note: Do not adjust the screws around
the Temperature Sensor hole. It could
ruin the Load Cell.

3.3.33 Installing the Load Cell PCB-Temperature Sensor-Position Sensor Assembly

5. Place the Position Sensor on the Magnet. It has a cavity allowing it to rest squarely,
aligned with the screw holes. (See Figure 3-157.) The Ratio Beam pin must be
centered in the hole in the back. (See Figure 3-158.)
Ratio Beam
Pin centered
in PSB hole
Cavity
under PSB
clears Ratio
Beam Vane
Figure 3-157. Position Sensor on the Magnet. Figure 3-158. Pin centered in PSB.
6. Install the Ratio Beam Ribbon Cable on the PCB and the Contact Board.

3.3.34 Setting the Up/Down Stop Screw on Block Style Load Cells
This procedure is required when either the Ratio Beam has been removed or replaced, or when
the Position Sensor has been replaced.
1. Disconnect the Ribbon Cable from the Contact Board to the Load Cell PCB.
2. The Load Cell must be completely reassembled and installed in the balance
Housing.
3. Plug the Ribbon Cable from the top of the Load Cell PCB into the Main PC Board.
4. Attach a Voltmeter (DC range) to the pins on the Load Cell PCB test connector, as
shown in Figure 3-159.
5. Apply power to the balance.
Test Connector
Test Connector
To Voltmeter
Figure 3-159. Load Cell PCB Test Connector. Figure 3-160. Test Connector Detail.
6. Measure the voltage with the Ratio Beam at the bottom of the Up/Down Stop Screw.
7. Carefully lift the Ratio Beam with
thumb and forefinger until it is at
the top of the Up/Down Stop
Screw. Measure the voltage again.
8. If the two voltage values either side
of zero are not of the same
magnitude, e.g. +2 V and –1.6 V,
the vertical stop must be adjusted
until the values are symmetrical.
Maximum difference is 0.2 Volts.
Figure 3-161. Up/Down Stop Screw
9. To adjust the Up/Down Stop Screw,
turn the Screw and repeat Steps 2 and 3 until the readings are within specifications.
(See Figure 3-161.)

CHAPTER 4 TESTING
4.1 TESTING
Before and after servicing the balance, an operational test and various performance tests
should be made to confirm that the balance meets specifications. Turn the balance on and
allow it to warm up. After it reaches ambient temperature, allow it to run for at least one more
hour before performing these tests.
NOTE:
Make sure the test area is free from drafts and that the balance rests on a level
and vibration-free surface.
4.1.1 TEST MASSES REQUIRED

The masses required to test the Ohaus Pioneer balances must meet the requirements of ASTM
Class 1 or OIML E1 Tolerance. The mass values are listed in Table 4-1.
TABLE 4-1. TEST MASSES REQUIRED
CAPACITY (g) SPAN MASSES (g) LINEARITY MASSES (g)
65 50 20/50
110 100 50/100
210 200 100/200
150 150 100/150
310 300 150/300
410/100 400 200/400
510 500 200/500
1500 1500 1000/1500
2100 2000 1000/2000
3100 3000 1500/3000
4100/1000 4000 2000/4000
4100 4000 2000/4000
4.2 Operational Test

1. Connect a functioning Power Adapter to the balance power receptacle located at the
rear of the balance.
2. Plug the Power Adapter into a suitable power source.
4.3 Segment Display Test

Turn the balance on, and ensure that all segments are enabled and displayed briefly.
The balance’s model number appears next, followed by a software revision number.
This is a Segment Display Test. Figure 4-1 is a full display test. (See Figure 4-1.)
Figure 4-1. Segment Display

CHAPTER 4 TESTING
4.4 Performance Tests – Precision and Analytical Balances
Accurate performance of the Pioneer balances is determined by a series of four performance

tests. The displayed readings are compared with the tolerances listed in Tables 4-2 and 4-3.
Tolerance values are expressed in counts. A one-count difference is shown in the last digit on
the balance display.
TABLE 4-2. TOLERANCES – PRECISION MODELS

Performance Test TOLERANCE – COUNTS
150g 210g 310g 410g 510g 1500g 2100g 3100g 4100g
Precision (counts) ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1
Off Center Load (mg) ±2 ±2 ±2 ±3 ±30 ±30 ±30 ±30 ±40
Repeatability (mg) ±1 ±1 ±1 ±1 ±10 ±10 ±10 ±10 ±10
Linearity (mg) ±2 ±2 ±2 ±2 ±20 ±20 ±20 ±20 ±40
TABLE 4-3. TOLERANCES – ANALYTICAL MODELS

Performance Test TOLERANCE – COUNTS
65g 110g 210g

Precision (counts) ±1 ±1 ±1
Off Center Load (mg) ±0.2 ±0.2 ±0.3
Repeatability (mg) ±0.1 ±0.1 ±0.1
Linearity (mg) ±0.2 ±0.2 ±0.3
NOTE:
The following performance tests are used to evaluate balance operation before
and after repairs. The balance must meet the requirements specified in each test
as well as the specifications listed in Tables 1-1 – 1-4.
Before proceeding with the following tests, the balance should be warmed up for
at least five minutes, and calibrated. (See Appendix A.)
4.4.1 Precision Test – Precision and Analytical Balances
The Precision Test measures the Standard Deviation of a set of similar weight readings, which
should match the specification for each model, listed in Tolerance Tables 4-1 and 4-2.
1. Tare the balance. The reading on the display should be 0g.
2. Select a mass weighing near the maximum capacity of the balance, and place it on
the center of the Pan. Observe and record the reading.
3. Remove the mass. The reading should return to 0g ±1 count.
4. Repeat this test three times. The reading should be within ±1 count of the reading
recorded. If so, the balance passes the Precision Test.

CHAPTER 4 TESTING
4.4.1 Precision Test – Precision and Analytical Balances
5. If the deviation for any set of readings (using the same mass placed on the center of
the Pan) is greater than the tolerance listed in Table 4-1 or 4-2, the balance does not
meet the precision specification. Inspect and correct the following areas:
5.1. Check for mechanical obstructions. Any foreign object touching any part of the
moving assemblies will cause a balance to fail the Precision Test. Inspect and
correct as necessary.
5.2. An error in the Off-Center Load Adjustment can affect the results of the
Precision Test. Inspect and correct if necessary. See the next section.
4.4.2 Off-Center Load Test

The Off-Center Load Test is used to determine whether displayed weight values are affected by
moving the sample to different areas of the Pan. See Figure 4-2.
Mass Locations
Figure 4-2. Mass Placement Locations

for Off-Center Load Test.
1. Place a mass weighing half of the balance’s capacity in the center of the Pan.
2. Press the On/Off button to return the reading to zero.
3. Move the mass halfway to the rear of the Pan and note the reading.
4. Move the mass halfway between the center and the left edge of the Pan and note the
reading.
5. Repeat this test for the right and front edges and note the readings.
Note any differences in the displayed weight reading at all positions. See Tables 4-2
and 4-3 for maximum allowable variance for each of the four positions.

CHAPTER 4 TESTING
4.4.3 Off-Center Load Adjustment for Precision Models

NOTE:
Do not attempt these adjustments unless the balance is free from drafts.
The balance is very sensitive and adjustments will be affected.
1. Set Auto-Zero to Off, in Menu Setup.
2. Open the balance. (See
Section 3.1.)
3. Reinstall the Pan.

4. Plug the power cord into the
balance and turn it on.
5. Place a mass that weighs the
balance’s full capacity on the
center of the Pan.
Turn in direction shown by arrows. For errors
6. Press O/T (the center button) front to back turn both adjustments the same
direction. For side to side errors turn in
to tare the balance and return opposite directions.
the displayed weight to 0g.
Move the mass to the front,
back, left and right edges of
the Pan. Note the displayed
values.
7. Correct any errors by turning
Corner-load Adjusting screws
as shown in Figures 4-3 and
4-4. Use a nut driver.
8. Adjust as shown until the Figure 4-3. Off-Center Load Adjustments on
tolerance is +/-5 counts. Pioneer Precision Balance.
9. Use small adjustments, no
more than ¼ turn at
time.Repeat Off-Center Load
Test.
10. Turn the balance OFF.
11. Remove the Platform.
12. Re-assemble the balance. Adjustment
(See Section 3.3.11.) Screw Holes
13. Turn Auto-Zero back to On,

in Menu Setup.
Figure 4-4. Off-Center Load Adjustment screw

holes on Precision models.

CHAPTER 4 TESTING
4.4.4 Off-Center Load Adjustment for Analytical Models

NOTE:
1. Set Auto-Zero to Off, in Menu Setup.
2. Open the balance. (See
Section 3.1.)
+ –
– +

balance’s full capacity on the
center of the Pan. Turn in direction shown by arrows. For errors
front to back turn both adjustments the same
6. Press O/T (the center button) direction. For side to side errors turn in
to tare the balance and return opposite directions.
the displayed weight to 0g.
Move the mass to the front,
back, left and right edges of
the Pan. Note the displayed – –
values.
7. Correct any errors by turning

Corner-load Adjusting screws
as shown in Figures 4-5 and
4-6. Use a 6mm nut driver.
8. Adjust as shown until the Figure 4-5. Off-Center Load Adjustments on

tolerance is +/-5 counts. Pioneer Analytical Balance.
9. Use small adjustments, no

more than ¼ turn at time.
10. Repeat the Off-Center Load

Test.
Adjustment
11. Turn the balance OFF. Screw Holes
12. Remove the Platform.
13. Re-assemble the balance.
14. Turn Auto-Zero back to On,
in Menu Setup.
Figure 4-6. Off-Center Load Adjustment screw

holes on Analytical models.

CHAPTER 4 TESTING
4.4.5 Off-Center Load Adjustment for Block Style Models
NOTE:
Adjust the Block Style Load Cell by removing

material from the locations indicated in Figure
4-7. Use a few strokes with a round needle
file exerting slight pressure.
Warning
– Do not file at the edge at the flexible
bearing positions.
– On completion of the adjustments, clean
the filing sites by removing the grindings
with adhesive tape (do not blow the
grindings away!).
1. Set Auto-Zero to Off, in Menu
Setup.
2. Open the balance. (See Section

3.1.)


balance’s full capacity on the center
of the Pan.
Figure 4-7. Using a Needle File to adjust Off
6. Press O/T (the center button) to Center Load on Block Style Load Cells.
tare the balance and return the
displayed weight to 0g. Move the mass to the front, back, left and right edges of the
Pan. Note the displayed values.
7. Correct any error by filing at one or two of the marked positions. (See Figure 4-7.)
8. Adjust as shown until the tolerance is +/-5 counts.
9. Repeat Off-Center Load Test.

10. Turn the balance OFF.
11. Remove the Platform and re-assemble the balance. (See Section 3.3.11.)
12. Turn Auto-Zero back to On, in Menu Setup.

CHAPTER 4 TESTING
4.4.6 Repeatability Test
Repeatability is the Standard Deviation of a set of similar weight readings.
Requirements:
– To perform this test a single mass must be used for all readings.
– The test mass should be approximately ½ of the capacity of the instrument.
– Wear gloves when handling the mass.
Before starting a repeatability test, set up the instrument as follows:
Set Up:
Enter the menu and adjust and record the following settings:
A. Set the Filter level to medium or the center of its range.
B. Set the AZT (Auto Zero Tracking) to .5d or its lowest setting. Do not turn it off.
C. Set the instrument to display the same units as the performance specifications.
(Usually kg, g, or mg)
Record Settings:
Filter Level Setting = ____________
Auto Zero Tracking Setting = ____________
Displayed Units = ____________
Mass Used = ____________
TEST PROCEDURE:
1. Zero the instrument, if it does not read zero.
2. Using a test mass approximately half the capacity of the instrument, place the mass on
the center of platform. Record the reading on the worksheet provided.
3. Remove the mass from the platform.
4. Repeat this test starting at Step 1 until you record a total of ten readings
Fill in the worksheet (Table 4-4) with the ten (10) readings.

CHAPTER 4 TESTING
4.4.6 Repeatability Test
TABLE 4-4. REPEATABILITY WORKSHEET

n Reading Delta = Reading – Mean Delta x Delta
1
2
3
4
5
6
7
8
9
10
n = number of Reading Mean = Sum of readings / 10 Delta = Reading – Mean
Standard Deviation = Square Root of (sum of (Delta x Delta) / 9)
5. Add the ten readings and divide the total by 10 to find the Mean (average).
6. Mean = (Reading 1 + Reading 2 + Reading 3 + Reading 4 + Reading 5
+ Reading 6 + Reading 7+ Reading 8 + Reading 9 + Reading 10) / 10
Mean =________
7. Calculate the Delta for each reading and record in the work sheet.
Delta = Reading – Mean

8. Calculate the Delta x Delta for each reading and record in worksheet.
9. Add the ten Delta x Delta values and divide by 9
10. Calculate the Standard Deviation by taking the square root of the result from Step 9.
Standard Deviation =___________
Note: If the balance does not meet specifications, move it to a suitable location, ensure
that it is level, and try again. If it still does not meet specifications, perform a service
calibration, and try again. (See Appendix B for Service Calibration.)

CHAPTER 4 TESTING
4.4.7 Linearity Test
This test is used to determine the linearity of the unit throughout its operating range.
The displayed readings are compared with the tolerances listed in the specifications for the
instrument. (See Specifications Tables, Chapter 1.) Tolerance values are expressed in counts.
A one-count change is equal to the last digit shown on the scale display.
The masses used to perform this test can be utility masses.
NOTE:
The balance must be warmed up prior to performing these tests, and must pass the
Precision, Off-Center Load Test and Repeatability Tests, and be calibrated before
the Linearity Test may be performed.
The Reference Mass should be approximately 1/8 of the full capacity of the balance.
USE THE SAME REFERENCE MASS THROUGHOUT THE LINEARITY TEST.
1. Press ZERO to zero the display.
2. Place the Reference Mass in the center of the pan and record the exact value (all
decimal places) displayed.
3. Remove the Reference Mass and verify that the display returns to zero. If it does not,
disregard the reading, press ZERO to re-zero the display, and repeat the process.
4. Place a mass equal to ¼ of the full scale capacity on the platform and press ZERO.
5. Add the Reference Mass to the center of the platform and record the value.
7. Place a mass equal to ½ of the full-scale capacity on the platform and press ZERO.
10. Place a mass equal to ¾ of the full scale capacity on the platform and press ZERO.
13. Calculate the weight differences between the readings as shown below.
14. The maximum difference should be less than or equal to the Linearity specification
for the instrument. (See Specification Tables, Chapter 1.)

CHAPTER 4 TESTING
4.4.7 Linearity Test
Record Readings
Reading 1 Reference Weight added to zero ________________
Reading 2 Reference Weight added at ¼ full-scale capacity: ________________
Reading 3 Reference Weight added at ½ full-scale capacity: ________________
Reading 4 Reference Weight added at ¾ full-scale capacity: ________________
Calculate Differences
Reading 1 – [(Reading 1 + Reading 2) / 2] = ________________
Maximum Difference _______________
The difference in the weights of the test mass should be within the tolerance in Table 1-2. If not,
perform a Standard Calibration – both Span and Linearity (see Appendix A) and repeat the test.
If the balance remains out of tolerance, the Load Cell may need to be repaired.

CHAPTER 5 PARTS LISTS & DIAGRAMS
This section contains exploded views of the Pioneer series balances. The exploded view
drawings are designed to identify the parts which can be serviced on the balance in the field.
There are many Pioneer models that have the same parts. There are eight diagrams and parts
lists, covering the full range of models, as follows:
Precision Balances
Section 5.1: Precision Round Pan Balance: Housing & Parts
Section 5.2: Precision Round Pan Balance, InCal: Housing & Parts
Section 5.3: Precision Square Pan Balance, InCal: Housing & Parts
Section 5.4: Precision Draft Shield Balance: Housing & Parts
Analytical Balances
Section 5.5: Analytical Balance: Housing & Parts
Load Cells
Section 5.6: Precision Load Cell & Parts (including InCal)
Section 5.7: Analytical Load Cell & Parts (including InCal)
Section 5.8. Block Style Load Cell Assembly (including InCal)
Precision Precision Precision Precision Precision Analytical

Analytical
Round Pan Round Pan InCal* Square Pan InCal Draft Shield Draft Shield InCal* InCal*
PA512 PA512C PAJ603C PA213 PA213C PA64 PA64C
PA2102 PA2102C PAJ1003C PA413 PA413C PA114 PA114C
PA4102 PA4102C PAJ2003C PAJ603 PA214 PA214C
PA4101 PA4101C PAJ1003
PAJ812 PAJ2003
PAJ2102
PAJ3102
PAJ4102
PAJ2101
PAJ3101
PAJ4101
*InCal Balances have been produced with either traditional MFR or Block Style Load Cells.
NOTE:
In all cases where a part is replaced, the balance must be thoroughly checked
after the replacement is made. The balance MUST meet the parameters of all
applicable specifications in this manual.
If further technical information is needed, please contact:

Ohaus Corporation www.ohaus.com
19A Chapin Road
P.O. Box 2033 Tel: 973-377-9000
Pine Brook, NJ 07058-2033 USA Fax: 973-593-0359
In the United States call toll free, 800-526-0659 between 8:00 a.m. and 6:00 p.m. EST.

5.1 PRECISION ROUND PAN BALANCE: HOUSING & PARTS
Figure 5-1. Precision Round Pan Balance: Housing & Parts

5.1 PRECISION ROUND PAN BALANCE: HOUSING & PARTS
TABLE 5-1. PRECISION ROUND PAN BALANCE: HOUSING & PARTS

Drawing Item Description
1 Weigh Below Cover
2 Leveling Feet (2)
3 Bottom Housing & Legal-for-Trade Lock
4 Cable Set
5 Load Cell
6 Load Cell Cover
8 EMC Plate
9 Pan Support
10 Weighing Pan
12 Function Label
13 Top Housing
14 Liquid Crystal Display (LCD)
15 Main Printed Circuit Board
80 Power Adapter
For all Pioneer Models, see specific parts lists through your Ohaus distributor.

5.2 PRECISION ROUND PAN, INCAL BALANCE: HOUSING & PARTS
Figure 5-2. Precision Round Pan, InCal Balance: Housing & Parts.

5.2 PRECISION ROUND PAN, INCAL BALANCE: HOUSING & PARTS
TABLE 5-2. PRECISION ROUND PAN, INCAL BALANCE:

HOUSING & PARTS*
1 Weigh Below Cover
2 Leveling Feet (2)
4 Cable Set
Load Cell:
5
5a=Traditional MFR, 5b=Block Style
6 Load Cell Cover
8 EMC Plate
9 Pan Support
10 Weighing Pan
12 Function Label
13 Top Housing
80 Power Adapter
*For details on Load Cell and InCal Mechanism parts, see Section 5.6.

5.3 PRECISION SQUARE PAN, INCAL BALANCE: HOUSING & PARTS
Figure 5-3. Precision Square Pan, InCal Balance: Housing & Parts.

5.3 PRECISION SQUARE PAN, INCAL BALANCE: HOUSING & PARTS
TABLE 5-3. PRECISION SQUARE PAN INCAL BALANCE: HOUSING & PARTS*
1 Weigh Below Cover
2 Leveling Feet (2)
4 Cable Set
5 Load Cell
6 Load Cell Cover
8 EMC Plate
9 Pan Support
10 Weighing Pan
12 Function Label
13 Top Housing
80 Power Adapter

5.4 PRECISION DRAFT SHIELD BALANCE: HOUSING & PARTS
11
9
80 10
12
13
6
5b
5a
14 4
15
2
3
1
Precision Balance with Draft Shield: Housing & Parts
Figure 5-4. Precision Draft Shield Balance: Housing & Parts.

5.4 PRECISION DRAFT SHIELD BALANCE: HOUSING & PARTS
TABLE 5-4. PRECISION DRAFT SHIELD BALANCE: HOUSING & PARTS*

1 Weigh Below Cover
2 Leveling Feet (2)
4 Cable Set
Load Cell:
5
6 Load Cell Cover
7 Draft Shield Glass (4 sides)
8 EMC Plate
9 Draft Shield Posts
10 Weighing Pan
11 Draft Shield Top
12 Function Label
13 Top Housing
80 Power Adapter

5.5 ANALYTICAL BALANCE: HOUSING & PARTS
Figure 5-5. Analytical Balance: Housing & Parts.

5.5 ANALYTICAL BALANCE: HOUSING & PARTS
TABLE 5-5. ANALYTICAL BALANCE: HOUSING & PARTS*

1 Weigh Below Cover
2 Leveling Feet (2)
4 Cable Set
Load Cell:
5
6 Load Cell Cover
7 Draft Shield Glass (4 sides)
8 EMC Plate
9 Draft Shield Posts
10 Weighing Pan
11 Draft Shield Top
12 Function Label
13 Top Housing
80 Power Adapter

5.6 PRECISION LOAD CELL & PARTS (INCLUDING INCAL)
Figure 5-6. Precision Load Cell & Parts (including InCal).

5.6 PRECISION LOAD CELL & PARTS (INCLUDING INCAL)
TABLE 5-6. PRECISION LOAD CELL & PARTS (INCLUDING INCAL) PARTS
1 Top Flexure Arm Assembly
2 Ratio Beam
3 Position Sensor Board
4 Ratio Beam Flexures
5 Vertical Flexure
6 Bottom Flexure Arm Assembly
7 Ribbon Cable from PSB to Contact Board
8 Hanger
9 LED Assembly
10 InCal Weight Arm Assembly
11 InCal Motor Assembly
12 InCal Weight Covers
13 InCal Weight Lifters
14 InCal Weights:
14a=InCal Weights for Balance up to 410g
14b=InCal Weights for Balance over 410g

5.7 ANALYTICAL LOAD CELL & PARTS (INCLUDING INCAL)
1
5
7
10
4
11
12
13
14
Pioneer Analytical
InCal Parts Load Cell w/ InCal Parts
Figure 5-7. Analytical Load Cell & Parts (including InCal).

5.7 ANALYTICAL LOAD CELL & PARTS (INCLUDING INCAL)
TABLE 5-7. ANALYTICAL LOAD CELL & PARTS (INCLUDING INCAL)

1 Top Flexure Arm Assembly
2 Ratio Beam
3 Position Sensor Board (PSB)
4 Ratio Beam Flexures
5 Vertical Flexure Assembly
6 Bottom Flexure Arm Assembly
7 Ribbon Cable from PSB to Contact Board
10 InCal Weight Arm
11 InCal Motor
12 InCal Weight Covers
13 InCal Weight Lifters
14 InCal Weights

5.8 BLOCK STYLE INCAL LOAD CELL & PARTS
Pioneer Block Style

Load Cell with InCal
Figure 5-8. Block Style Incal Load Cell & Parts.

5.8 BLOCK STYLE INCAL LOAD CELL & PARTS
TABLE 5-8. BLOCK STYLE INCAL LOAD CELL & PARTS

1 Position Sensor
2 Ratio Beam
3 Load Cell PCB
4 InCal Mechanism Assembly
5 InCal Motor


APPENDIX A STANDARD CALIBRATION
APPENDIX A. STANDARD CALIBRATION
A.1 CALIBRATION
There are two types of standard calibration for Pioneer balances: Span and Linearity. Span
calibration sets the balance's weighing range, within pre-set limits, for zero and a weight value
at or near the balance's capacity. Linearity calibration minimizes deviation between actual and
displayed weights within the balance's weighing range. Three weight values are used: zero, a
weight value in the middle of the balance's weighing range and a weight value at or near the
balance's specified capacity.
A.1.1 Calibration Masses
Before beginning calibration, ensure that masses are available. If you begin calibration and
realize calibration masses are not available, exit the menu. The balance will retain previously
stored calibration data. See Table 4-1 for specified masses for all Pioneer models. Masses
must meet or exceed ASTM Class 1 or OIML E1 Tolerance. Calibration masses are available
as accessories from any Ohaus dealer.
A.2 Span Calibration
With the balance on, press and release Unit/Menu. until

CAL appears. Press Yes (the On/Off button).
.CAL.
SPAN appears. Press Yes.
SPAn
The specified mass weight flashes.
(Pressing No will toggle to alternate mass weight.)
Place the indicated weight in the center of the Pan. 4000
Busy flashes. After a few seconds Clear Pan flashes.
Remove the mass from the Pan.
BUSY
- - - 0 - - - flashes, as the balance calibrates a zero
setting.
---0---
When calibration finishes, Done appears briefly, and the
balance returns to weighing mode.
Done
NOTE: If calibration fails, ensure that the test area is free from drafts and the surface the
balance rests on is level and free of vibrations. Then try to calibrate again. If it continues to fail,
there may be an internal problem. To resolve internal problems, follow procedures in Chapter 3.
Pioneer™ Balances Service Manual A-1 Ohaus Corporation www.ohaus.com

APPENDIX A STANDARD CALIBRATION
A.3 Linearity Calibration
With the balance on, press and release Unit/Menu. until

CAL appears. Press Yes (the On/Off button).
.CAL.
SPAN appears. Press No. Linear appears. Press Yes.
(If PUSH flashes, place maximum weight on the Pan.) Linear
After a few seconds Clear Pan flashes.
Clear
- - - 0 - - - flashes, as the balance calibrates a zero
setting.
---0---
The specified middle weight flashes.
Place the indicated weight in the center of the Pan.
2000
BUSY
The specified maximum weight flashes.
4000
BUSY
- - - 0 - - - flashes, as the balance re-calibrates the zero
setting.
---0---
When calibration finishes, Done appears briefly, and the
balance returns to weighing mode.
Done
Note:
Be careful not to touch the scale or the table while calibration is in progress,
as it will cause the process to fail.
Ohaus Corporation www.ohaus.com A-2 Pioneer™ Balance Service Manual

APPENDIX B SERVICE CALIBRATION
APPENDIX B. SERVICE CALIBRATION
This section describes the Service Menu and sub-menus, which allow authorized service
personnel to perform factory calibrations.
B.1 Entering the Service Menu
Turn the balance off.
Enter the Service Menu by pressing and holding

On/Zero Off and Unit together. As the balance powers
up, SERVICE appears followed by RAMP. ServICe
Press Yes to select Ramp.
Press No to advance to Span Calibration.
ramMp
B.2 Ramp
The first sub-menu in the Service Menu is Ramp. The ramp display shows the percentage of
use of the A to D circuit. The actual value is not as important as how it changes. It should
increase as the weight on the balance is increased. The ramp display should remain constant
without fluctuations.
To view the Ramp value, press Yes. A number will

appear and should be constant. Place masses on
the balance from minimum to maximum capacity.
The reading will increase but should not fluctuate. The
22.8 %
example at right is with no weight on the Pan.

The reading will vary with other balances.
Span
To exit the ramp function, press No.
The balance advances to the Span calibration menu.
Press Yes to perform Span Calibration.
(See next page.)
Pioneer™ Balances Service Manual B-1 Ohaus Corporation www.ohaus.com

B.3 Span Calibration
Span calibration from the service menu allows you to set a new zero and maximum setting.
This is distinct from user level span calibration, which allows a user to adjust the zero and
maximum setting within the range established by the service menu span setting.
NOTE:
The balance should be perfectly level before attempting a span calibration.
Use the balance’s leveling feet (at the rear of the balance), together with the
leveling bubble which is just to the right of the Display.
Be careful not to touch the scale or the table while calibration is in progress,
as it will cause the process to fail
Enter the Service Menu by pressing and holding

On/Zero Off and Unit together. As the balance powers
up, SERVICE appears followed by RAMP. ServICe
Press No to advance to Span Calibration.
ramp
SPAN appears. Press Yes.
SPAn
The specified maximum mass weight flashes.
4000
BUSY
- - 0 - - flashes, as the balance calibrates a zero setting.
--0--
When span calibration finishes, Linear appears.
Press Yes, to proceed to Linear Calibration.
To exit, press No and then Yes to end service
calibration.
Linear
NOTE: If calibration fails, ensure that the test area is free from drafts and the surface the
balance rests on is level and free of vibrations. Then try to calibrate again. If it continues to fail,
there may be an internal problem. To resolve internal problems, follow procedures in Chapter 3.
Ohaus Corporation www.ohaus.com B-2 Pioneer™ Balance Service Manual

B.4 Linear Calibration
Linear calibration automatically follows Span calibration. To start from the Service Menu,
press and hold On/Zero Off and Unit together. As the balance powers up, SERVICE appears
followed by RAMP. Press No twice, to bypass Ramp and Span calibration.
When Linear appears, press Yes.

(If PUSH flashes, place maximum weight on the Pan.) Linear
After a few seconds Clear Pan flashes.
Clear
- - - 0 - - - flashes for a few seconds, as the balance
calibrates a zero setting.
---0---
The specified middle weight flashes.
2000
BUSY
The specified maximum weight flashes.
Place the indicated weight on the center of the Pan.
4000
The specified middle weight flashes again.
Place the indicated weight on the center of the Pan.
2000
- - - 0 - - - flashes, as the balance re-calibrates the zero
setting...When calibration finishes, Done appears briefly.
Done
EndServ appears. If you have completed Service
Calibration, press Yes. Otherwise, press No to cycle
through the Service Menu again. endServ
When calibration is finished, the balance returns to the weighing mode.
Pioneer™ Balances Service Manual B-3 Ohaus Corporation www.ohaus.com

Ohaus Corporation www.ohaus.com B-4 Pioneer™ Balance Service Manual

APPENDIX C. SOFTWARE SERVICE TOOL INSTRUCTIONS
The Pioneer Software Service Tool is used for 5 purposes:
1. To restore EEPROM data, after the Position Sensor Board is replaced.
2. To install a new Load Cell.
3. To install a new Main Printed Circuit Board (PCB).
4. To update the software in the balance.
5. For diagnostics.
Install the software on a Personal Computer running Microsoft Windows NT 4.0 or later, or
Microsoft Windows 98 or later. Insert the CD and run Setup.exe.
After installation, run the program Service Tool. The program has 5 tabs across the top of the
screen. Click on the tab for the function you wish to perform. If the default settings for
communication have been changed, click on settings and change the settings in the software
to match.
Figure C-1. Com Port Configuration Menu.
Pioneer™ Balance Service Manual C-1 Ohaus Corporation www.ohaus.com

C.1 To Restore the EEPROM data:
1. Record the following information from the balance to be repaired:
1.1. Serial Number from the label on the back of the balance.
1.2. Model Number from the label on the back of the balance.
1.3. IDNR Number, just above the label on the back of the balance.
2. Contact Ohaus Corporation in Pine Brook NJ, and request the data file to download.
Provide the information recorded above.
3. After receiving the data file from Ohaus, continue with the following steps.
4. Connect the balance to the PC and start the Pioneer Software Service Tool.
5. Click the tab labeled Restore EEPROM.
Figure C-2. The Software Service Tool’s Restore EEProm Tab.
6. Enter the balance’s Serial Number and IDNR number.
7. Enter the path to the image file, or click the Change button to locate the file.
8. Click the Write Image File button.
9. The software will indicate the download progress. When complete, disconnect the
power from the back of the balance, then re-connect.
10. Perform Service Calibrations (see Appendix B). Test the balance.
Ohaus Corporation www.ohaus.com C-2 Pioneer™ Balance Service Manual

C.2 To Replace a Load Cell:
1. Follow the steps in Section 3-2 to replace the defective load cell.
2. Open the packet containing labels that was supplied with the replacement Load Cell.
These labels each contain a model number followed by the IDNR number.
Carefully select the label that matches exactly the model number of the balance.
3. Put the new label on the balance.
4. Power the balance from an AC adapter.
5. Connect the balance to your computer.
6. Start the Pioneer Service Tool Software.
7. Click on the tab labeled Replace Loadcell.
Figure C-3. The Software Service Tool’s Replace Load Cell Tab.
8. Enter the IDNR number (xxx.xx.xx.xxxx) from the label on the back of the balance.
9. Click the Start button.

C.3 Install New Main Printed Circuit Board (PCB).
1. Follow steps in Sections 3.1.3 to replace the PCB. Then connect the balance to your
computer.
3. Click on the tab labeled Replace PCB.
Figure C-4. The Software Service Tool’s Replace PCB Tab.
4. Enter the Serial Number value from the label on the back of the balance.
5. Enter the IDNR number (xxx.xx.xx.xxxx) from the label on the back of the balance.
6. Click the Start button

C.4 Update the Software in the Balance:
1. Connect the Balance to your computer.
3. Click on the tab labeled Download Software.
Figure C-5. The Software Service Tool’s Download Software Tab.
4. Enter the path to the file to download, or click the Change button to locate the file.
5. Click on the Start Download button.
6. When prompted, disconnect the power from the back of the balance, then re-connect.
7. The software will indicate the download process. When complete, disconnect the power
from the back of the balance, then re-connect.

C.5 Diagnostics
1. Connect the balance to your computer.
2. Start the Pioneer Software Service Tool.
3. Click on the tab labeled “Diagnostics.”
Raise
Lower
Figure C-6. The Software Service Tool’s Diagnostics Tab.
4. To test communications, click the Print button, or enter an RS232 Command String (from
Table 4-6), and click the Send button.
5. The scale’s response will be shown in the box on the right.
C.5.1 Incal Weight Mechanism Testing
Note: This procedure is used to test that the Incal Weight(s) move(s) smoothly. When the
weight(s) is in the lowered position, the display reading should be STABLE.
1. Click on one of the InCal Weight Control buttons: Raise or Lower.
2. Observe weight displayed on the balance.
A fluctuating display value indicates the weight is not stable. This could be because the weight
is not fully lowered and/or because it is touching something. To correct this symptom, follow the
procedures in Section 3.3.7 – 3.3.8 for Precision Load Cells; Sections 3.3.12 – 3.3.13 for
Analytical Load Cells; and Sections 3.3.17 – 3.3.19 for Block Style Load Cells with Internal
Calibration.

*80251533*
P/N 80251533 SERVICE MANUAL: PIONEER BALANCES

Service Manual: Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058-2033 (973) 377-9000

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SERVICE MANUAL

Material in this manual is subject to change.

© Copyright 2008 Ohaus Corporation, all rights reserved.

CHAPTER 3 MAINTENANCE PROCEDURES

Ohaus Corporation www.ohaus.com i Pioneer™ Balances Service Manual

CHAPTER 5 DRAWINGS AND PARTS LISTS

Appendix A STANDARD CALIBRATION

Appendix B SERVICE CALIBRATION

Pioneer™ Balances Service Manual ii Ohaus Corporation www.ohaus.com

Ohaus Corporation www.ohaus.com iii Pioneer™ Balances Service Manual

FIGURE NO. TITLE Page No.

Pioneer™ Balances Service Manual iv Ohaus Corporation www.ohaus.com

Ohaus Corporation www.ohaus.com v Pioneer™ Balances Service Manual

Pioneer™ Balances Service Manual vi Ohaus Corporation www.ohaus.com

Ohaus Corporation www.ohaus.com vii Pioneer™ Balances Service Manual

Pioneer™ Balances Service Manual viii Ohaus Corporation www.ohaus.com

Chapter 2 Troubleshooting – Contains a diagnosis/diagnostics chart and error code table.

Chapter 3 Maintenance Procedures – Contains preventive maintenance procedures and

1.2 SERVICE FACILITIES

• Work surface must be stable and level.

• Use an approved Electro-Static Device.

Pioneer™ Balances Service Manual 1-1 Ohaus Corporation www.ohaus.com

1.3 TOOLS AND TEST EQUIPMENT REQUIRED

1.3.2 Standard Tools and Test Equipment

TABLE 1-1. SPECIFICATIONS: EXTERNAL CALIBRATION MODELS (includes M Models)

Ohaus Corporation www.ohaus.com 1-2 Pioneer™ Balances Service Manual

TABLE 1-2. SPECIFICATIONS: INCAL MODELS (C & CM)

TABLE 1-3. SPECIFICATIONS: CARAT MODELS

Pioneer™ Balances Service Manual 1-3 Ohaus Corporation www.ohaus.com

TABLE 1-4. SPECIFICATIONS: GOLD MODELS (EXTERNAL CALIBRATION)

TABLE 1-5. SPECIFICATIONS: GOLD MODELS (INTERNAL CALIBRATION)

Ohaus Corporation www.ohaus.com 1-4 Pioneer™ Balances Service Manual

TABLE 1-6. ADMISSIBLE AMBIENT CONDITIONS

1.5 BALANCE OPERATION

Figure 1-1. Pioneer, Carat and Gold Series displays.

Pioneer™ Balances Service Manual 1-5 Ohaus Corporation www.ohaus.com

1.5.2 OVERVIEW OF THE CONTROLS

TABLE 1-7. FUNCTIONS OF DISPLAY CONTROLS

1.5.2 OVERVIEW OF THE DISPLAY INDICATORS

Figure 1-2. Pioneer Display Indicators.

Ohaus Corporation www.ohaus.com 1-6 Pioneer™ Balances Service Manual

1.5.4 Power OFF

1.5.5 Menu Setup

1.5.6 Menu Structure

Figure 1-3. Pioneer Menu Structure

Pioneer™ Balances Service Manual 1-7 Ohaus Corporation www.ohaus.com

1.5.7 The Load Cell

Magnet Bottom Flexure Arm Flexure

Figure 1-4. Load Cell Assembly.

Ohaus Corporation www.ohaus.com 1-8 Pioneer™ Balances Service Manual

1.6 Connecting the RS232 Interface

TABLE 1-9. COM 1 INTERFACE PIN CONNECTIONS

To enable External PRINT and/or ZERO/

Join the points by filling the gap:

Figure 1-6. Soldering points J1 and J2.

Pioneer™ Balances Service Manual 1-9 Ohaus Corporation www.ohaus.com

1.7 RS232 Commands

TABLE 1-10. RS232 COMMAND TABLE

Ohaus Corporation www.ohaus.com 1-10 Pioneer™ Balances Service Manual