Optional

Communicator

EDxtreme, EDjr,
and Communicator
Service Manual
2 EDxtreme, EDjr, and Communicator Service Manual
Table of Contents
Table of Contents .......................................................................................... 3
Safe Operation .............................................................................................. 5
Radio Safety ............................................................................................ 6
FCC Information ............................................................................................ 6
Modifications ............................................................................................ 6
EDxtreme Specifications ............................................................................... 7
Dynamometer Specifications ................................................................... 8
Communicator Specifications .................................................................. 8
Radio Specifications ................................................................................ 8
EDjr Specifications ........................................................................................ 9
Dynamometer Specifications ................................................................. 10
Introduction ................................................................................................. 11
Theory of Operation ............................................................................... 11
EDxtreme ............................................................................................... 11
EDX & Communicator Description .............................................................. 12
EDX Front Panel .................................................................................... 12
EDxtreme Connector ............................................................................. 13
Communicator Front Panel .................................................................... 13
Communicator Connectors .................................................................... 14
Power On and Annunciators ....................................................................... 15
EDjr Introduction ......................................................................................... 16
EDjr Description .......................................................................................... 16
EDjr Front Panel .................................................................................... 16
Power On and Annunciators ....................................................................... 17
EDxtreme Calibration Menu ........................................................................ 18
Calib. softkey ......................................................................................... 20
ClrCal softkey ........................................................................................ 21
O.Load softkey....................................................................................... 21
Capac softkey ........................................................................................ 21
Serial softkey ......................................................................................... 21
ROM softkey .......................................................................................... 21

EDxtreme, EDjr, and Communicator Service Manual 3

 Communicator Calibration Menu ................................................................. 22
Calibration Procedure for EDX and EDJr. ................................................... 22
Using Applied Load ................................................................................ 22
Using Key-In Values .............................................................................. 25
Testing and Troubleshooting ....................................................................... 26
Resetting Configuration Password......................................................... 26
Download Failure ................................................................................... 26
Keypad Test........................................................................................... 26
EDx and Communicator Wireline Testing .............................................. 26
EDx and Communicator RF testing (for systems equipped with radio) . 27
Keypad Continuity Test for Link Only .................................................... 28
Helpful Hints .......................................................................................... 30
Weighing and Force Measurement Practice.......................................... 30
Load Centering ...................................................................................... 30
Alignment ............................................................................................... 30
Proper Pin Fit ......................................................................................... 30
Torque and Bending .............................................................................. 30
Certified Gear ........................................................................................ 30
Calculating Tension in a System ........................................................... 31
Good Force Measurement Practice ............................................................ 32
Appendix 1: EDX, EDjr Disassembly Procedure ......................................... 33
Appendix 2: EDX, EDjr Assembly and Field Installation Procedure ............ 34
Technical Illustrations .................................................................................. 38

4 EDxtreme, EDjr, and Communicator Service Manual

Safe Operation
Keep all the following in mind as you use the EDX dynamometer.
The system capacity is equal to the rating of the dynamometers. The
shackle rating should not be used to determine lift capacity of the system.
The shackles are rated in metric tons. Thus the 12-ton shackles are rated to
26,450 lbf and are suitable for use on the 25,000 lbf dynamometer.
Any zeroed deadload must be considered as part of the ultimate load.
If you overload this dynamom-
eter you could suffer severe Although this instrument has a substantial overload protection rating, the
injuries or death. The total load instrument should not be used above the rated capacity. Doing so can
on the dynamometer should significantly impact fatigue life of the instrument and cause premature and
NEVER exceed the rated abrupt failure. If a higher capacity reading is needed, Dillon insists that a
capacity. larger instrument be used.
Safety is always a concern in overhead lifting and tensioning applications.
To limit your liability always insist upon factory supplied shackles and pins
and factory tested and certified safe optional equipment. All DILLON prod-
ucts are designed to meet the published Safe Working Load (SWL) and
Ultimate Safety Factor (USF) standards of the United States Military.
Do not grind, stamp or deform the metal on the dynamometer body in any
way.
Any significant damage or deformation to the loading element is cause for
evaluation by Dillon, particularly in the element side members to the right
and left of the display.
Relieve all torsional and off axis loads.
Apply load in the center of the shackle bow with this instrument.
Off center loading results in substandard performance.
Instrument requires time to stabilize when changing temperatures.
Use only the hardware supplied with this instrument. If no hardware was
supplied, insure that the mating pin and shackle bow is equivalent to the
hardware used at calibration. Otherwise substandard performance can
result.
Dillon recommends only using qualified rigging hardware and cannot
be responsible for unapproved hardware.
This instrument is not designed for the following:
• Applications that see rapid, dramatic temperature swings or thermal
shock. Wide variation in readings can occur.
• Environments with high electromagnetic fields such as cranes employ-
ing electromagnets to lift metal. These induce trace voltages that are
picked up within the load cell lead wiring and appear as inaccurate
loads.
• Intrinsically safe environments. This unit has not been Factory Mutual
tested.

EDxtreme, EDjr, and Communicator Service Manual 5

Radio Safety The radiated output power of this device is far below the FCC radio fre-
quency exposure limits. Nevertheless, the device shall be used in such
manner that the potential for human contact during normal operation is
minimized.
When connecting an external antenna to the device, the antenna shall be
placed in such a manner to minimize the potential for human contact during
normal operation. In order to avoid the possibility of exceeding the FCC
radio frequency exposure limits, human proximity to the antenna shall not
be less than 1 inch (2.5 cm) during normal operation. The antenna is
located at the connector panel on the Communicator.

FCC Information
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interfer-
ence that may cause undesired operation.

Agency Identification Numbers

US/FCC CAN/IC
KQL-PKLR2400 CAN2268391158A

The FCC states that any changes or modifications to this device that are not
Modifications expressly approved by Dillon may void the user’s authority to operate the
equipment

6 EDxtreme, EDjr, and Communicator Service Manual

EDxtreme Specifications*
Body Construction
Model Capacity x Resolution (normal/enhanced) and Overload Design

EDx–2.5K 2500 lbf x 2/0.5 1000 kgf x 1/0.2 10000 N x 10/2 Aircraft quality
2024 Aluminum
EDx–5K 5000 lbf x 5/1 2000 kgf x 2/0.5 20000 N x 20/5
700% Ultimate overload
EDx–10K 10000 lbf x 10/2 5000 kgf x 5/1 50000 N x 50/10 protection
EDx–25K 25000 lbf x 20/5 10000 kgf x 10/2 100000 N x 100/20 Aircraft quality
E4340 Alloy Steel
EDx–50K 50000 lbf x 50/10 20000 kgf x 20/5 200000 N x 200/50
500% Ultimate overload
EDx–100K 100000 lbf x 100/20 50000 kgf x 50/10 500000 N x 500/100 protection
EDx-160K 160,000 lbf x 100/50 75,000 kgf x 50/20 --------------
Aircraft quality
EDx-220K 220,000 lbf x 200/50 100,000 kgf x 100/20 -------------- E4340 Alloy Steel
400% Ultimate overload
EDx-330K 330,000 lbf x 200/100 150,000 kgf x 100/50 --------------
protection
EDx-550K 550,000 lbf x 500/200 250,000 kgf x 200/50 --------------

Model Dimensions Dimensions shown are nominal and subject to tolerances.

Model A B C D E F G H J
EDx–2.5K inch 10.6 5.0 7.8 1.06 0.75 15.3 13.4 1.36 1.69
mm 269 127 198 26 19 389 340 34 43
EDx–5K inch 10.6 5.0 7.8 1.06 0.75 15.3 13.4 1.36 1.69
mm 269 127 198 26 19 389 340 34 43
EDx–10K inch 11.4 5.3 8.1 1.38 1.00 17.8 15.8 2.17 2.28
mm 289 135 206 35 25 451 402 56 58
EDx–25K inch 11.5 5.3 7.9 1.97 1.38 21.6 18.8 3.67 3.25
mm 291 133 201 50 35 548 478 93 83
EDx–50K inch 13.7 6.0 9.0 2.75 2.00 29.7 25.2 5.7 5.0
mm 348 152 229 70 51 754 640 146 127
EDx–100K inch 15.8 6.8 10.3 3.88 2.75 40.5 34.3 9.3 7.3
mm 400 172 262 99 70 1029 870 235 184
EDx–160k inch 16.5 7.8 10.3 3.88 2.75 40.5 34.3 8.9 7.3
mm 419 197 262 99 70 1030 870 225 184
EDx–220k inch 18.0 7.8 11.0 5.00 3.25 47.7 40.5 11.2 7.8
mm 457 197 280 127 83 1211 1027 284 200
EDx–330k inch 21.0 8.8 12.6 5.25 3.75 53.9 45.6 12.3 9.0
mm 533 222 321 133 95 1368 1159 313 229
EDx–550k inch 27.0 9.8 17.5 8.5 5.00 75.8 62.8 17.9 13.0
mm 686 248 445 216 127 1925 1595 454 330

*Specifications subject to change.

EDxtreme, EDjr, and Communicator Service Manual 7

EDx Dynamometer Specifications Radio Specifications
Enclosure: Designed to NEMA4X/IP55. FCC Certified: For unlicensed low power devices. No radio
Suitable for continuous outdoor use. licensing or permits required for normal operation.* (In the
Accuracy: 0.1% of capacity.* US and Canada. Check local ordinances in other countries.)
Repeatability: 0.1% of capacity.* Frequency: 2.4 GHz spread-spectrum operates between 2.402 –
* Normal resolution mode with Dillon provided shackles. 2.478 GHz. Continuously and automatically changes
frequencies many times per second for consistent, reliable
Ultimate overload: See table on reverse.
communications.
Safe overload: 200% of capacity
Output level: 10 mW (20 dBm)
Body protection: Aluminum capacities are anodized. Alloy steel
Display update rate: 2 times per second with single dynamometer.
capacities are electroless-nickel plated.
Multi-instrument networks result in reduced updates.
Bearings: Unmatched repeatability attained by needle bearings in
Number of networks: 63 remotes can operate
shackle pin holes up to EDx-10K. Shackle pin acts as inner race.
independently in the same airspace with unique channels.
Shackles: Forged industry standard anchor shackles. Models up to
Number of links remote can control: Up to 15 addresses are
EDx-10K use precision machined shackle pin. Higher capacities
available per network channel.
use forged pin.
Configuration: Address and Network channels are
Display: 128 x 64 dot-graphic LCD display shows up to 6 digits 1.0” (26
front-panel configurable.
mm) high plus annunciators and softkeys. Digits are .11 inches
(7mm) thick for unmatched readability. Antenna: Integral antenna.
Display update rate: 2 times per second. Range: Open-air – Up to 300 feet, line-of-sight.
Indoors – Dependent upon installation site with 150 feet common.
Connector: Recessed sealed connector may be used for serial
communications or connection to a Communicator remote. Approval: FCC ID: KQL-PKLR2400
CAN ID: CAN2268391158A
RS-232 / RS-485 communication: Print or extract data easily.
Continuous output can drive a scoreboard. Configurable poll
character.
Calibration: Traceable to the National Institute of Standards and
Technology. Certificate included with curve of readings. Passes
only with three consecutive confirming runs, with all points in
specification.
Battery life: 320 hours typical use with two C-cell alkaline batteries.
40 hours typical with Radio Link system.
Operating temperature: -4° F to 140° F (-20° to 60° C)
Included with instrument: Carry case, batteries, manual and
certificate of calibration. EDx-50K and EDx-100K with shackles
include shackle crate and spacers. Weights
Options: Shackles. 2.4 GHz radio board. Display backlight.
Model Unit Weight with Approx. Shipping
Weight Shackles Weight

Communicator Specifications EDx–2.5K lb 4.3 8.6 13

kg 2.0 3.9 6

Enclosure: Designed to NEMA 3 / IP44 with optional sleeve. EDx–5K lb 4.4 8.7 13
Suitable for protected outdoor use. kg 2.0 3.9 6
Instrument size: 9.0 x 4.6 x 1.8 inch (228 x 117 x 45mm). EDx–10K lb 5.6 14 22
Accuracy: Not applicable. Only sends and receives digital kg 2.5 6.1 10
information. EDx–25K lb 16 40 46
Display: 128 x 64 dot-graphic LCD display can show full readings kg 7.3 18 21
up to 5 instruments.
EDx–50K lb 25 96 125
Battery life: 40 hours radio or 45 wireline using four kg 11 43 56
AA alkaline batteries under typical use.
Operating temperature: -4° F to 140° F (-20° to 60° C) EDx–100K lb 38 238 296
kg 17 108 134
Connectors: Sealed connectors may be used for serial communi-
cations and wired connection to an EDxtreme dynamometer. EDx–160K lb 54 250 325
RS-232 communication: Print or extract data easily. Continuous kg 25 114 145
output can drive a scoreboard. Configurable poll character. EDx–220K lb 70 410 480
Included with remote: Carry case and batteries. kg 32 186 218
Accessories: Rubberized case protector sleeve. Remote wall EDx–330K lb 120 650 750
mount bracket. Serial and remote cable assemblies. kg 54 295 340
EDx–550K lb 250 1490 1600
kg 113 675 725
Communicator lb 1.0 n/a 10
kg 0.5 5

8 EDxtreme, EDjr, and Communicator Service Manual

EDjr Specifications*
*Specifications subject to change.

Capacity x resolution
EDjr–2.5K 1 2500 lbf x 2 1000 kgf x 1 10000 N x 10
EDjr–5K 1 5000 lbf x 5 2000 kgf x 2 20000 N x 20
1
EDjr–10K 10000 lbf x 10 5000 kgf x 5 50000 N x 50
EDjr–25K 1 25000 lbf x 20 10000 kgf x 10 100000 N x 100
1
700% Ultimate overload protection.
Body Construction is Aircraft quality 2024 Aluminum

Dimensions Dimensions shown are nominal and subject to tolerances.

Model A B C D E F G H I J

EDjr–2.5K inch 8.4 5.0 6.9 0.75 0.50 11.6 10.8 1.20 2.03 1.16
mm 213 127 174 19 13 296 274 30 52 29
EDjr–5K inch 10.6 5.0 7.8 1.06 0.75 14.8 13.4 1.41 2.94 1.69
mm 269 127 198 27 19 375 340 35 75 43
EDjr–10K inch 11.4 5.3 8.1 1.38 1.00 17.8 15.8 2.22 4.03 2.28
mm 289 135 206 35 25 451 402 56 102 58
EDjr-25k inch 11.5 5.3 7.9 1.97 1.38 21.6 18.8 3.67 4.53 3.25
mm 291 133 201 50 35 548 478 93 115 83

EDxtreme, EDjr, and Communicator Service Manual 9

EDjr Dynamometer Specifications Weights
Model Unit Weight with Approx. Shipping
Enclosure: Designed to NEMA4X/IP55. Weight Shackles Weight
Suitable for continuous outdoor use. EDX–2.5K lb 2.9 3.9 6
kg 1.3 1.8 3
Accuracy: 0.2% of capacity.
EDX–5K lb 4.5 7.8 10
Repeatability: 0.2% of capacity. kg 2.0 3.9 5
EDX–10K lb 6.4 14.3 18
Ultimate overload: 700%
kg 2.9 6.5 8
Safe overload: 200%
EDX–25K lb 17.0 41 47
Display: 128 x 64 dot-graphic LCD display shows all kg 8.2 19 21
digits 1.0” (26 mm) high plus annunciators and
softkeys.
Display update rate: 2 times per second.
Peak hold sampling rate: 2 times per second typical.
RS-232 communication: Not available.
See Dillon EDxtreme.
Calibration: Traceable to the National Institute of
Standards and Technology. Calibration card in-
cluded.
Battery life: 320 hours typical use with two C-cell
alkaline batteries.
Operating temperature: -4° F to 140° F (-20° to 60° C)
Included with instrument: Batteries, manual and
calibration card.
Optional accessories: Carry case.

10 EDxtreme, EDjr, and Communicator Service Manual

Introduction

Theory of Operation

Electronic Dynamometer With proper alignment, the electronic dynamometer is a high precision
device. When force is applied, the dynamometer will elongate or stretch.
This stretching force passes through strain gauges bonded to the walls of
the dynamometer. The strain gauges sense this tiny force. A voltage is
applied to the strain gauges (excitation voltage). As the dynamometer
elongates the resistance of the strain gauges changes. This changes the
output voltage (signal voltage) of the strain gauges. The dynamometer
measures this voltage as an analog signal. This analog signal passes
through an analog to digital (A to D) converter, generating counts. These
counts are the determining factor for precision measurement. Calibrating the
dynamometer will assign an average number of counts to a specified force
or applied load.

Communicator A remote display designed to mimic the operation of a single or multiple

electronic dynamometers. As a remote display for multiple dynamometers it
will also provide the ability to see the total force. In RS-485 or wire-line
mode, it provides connectivity to a single dynamometer. It has the ability to
be a remote power source and allow for distances of up to 1500 feet be-
tween the communicator and the link. The radio mode provides the ability to
communicate to multiple dynamometers. Operating at 2.4GHz hopping
spread spectrum frequency, the communicator will communicate at 2.4GHz
but on multiple channels. As a whole, the communicator provides an inter-
face between the dynamometer and other devices such as computers and
printers. It also allows one operator to monitor multiple dynamometers
individually or in a system working together.

The EDxtremeTM (EDX) electronic dynamometer from Dillon is a force

EDxtreme measurement load sensor and digital readout in one instrument. The EDX
can be used to measure tension or weight. It can operate stand-alone or be
coupled with a remote Dillon Communicator, via radio communication or
direct wire connection, for improved convenience, functionality and safety.
Be sure to read the safety precautions found in the Safe Operation section.

If you overload this dynamom-

eter you could suffer severe
injuries or death. The total load
on the dynamometer should
NEVER exceed the rated
capacity.

EDxtreme, EDjr, and Communicator Service Manual 11

EDX & Communicator Description
The EDX comes in several weight capacities. All have the same front panel,
EDX Front Panel shown in Figure 1.

Figure 1
EDxtreme front panel

EDX Keys There are four “hard” keys and four “soft” keys. The hard keys are perma-
nently labeled and the soft keys are just below the display. The soft key
functions change and the key label appears above each key on the display.
Sometimes the individual soft keys are referred to as the F1, F2, F3 and
F4 keys as numbered from left to right.

12 EDxtreme, EDjr, and Communicator Service Manual

 On/Off key Use this key to turn the unit on and off.

If you press and hold the

ZERO key for five seconds, the ZERO key Use this key to zero the force indicated
EDX display will show the zero on the display.
reference calibration point.

ESC key Use this key to escape from portions of

the menu structure and return to previ-
ous choices or displays.

Arrow key Use this key to access any available soft

keys not currently viewed.

The connector on the EDxtreme is recessed for protection. It is used to

EDxtreme Connector connect the instrument to a Communicator remote display/controller, printer
or external power supply. See your Dillon distributor for details.

Figure 2 shows the Dillon Communicator. This is a battery powered, radio-

Communicator Front linked (or wired) remote display and control unit.
Panel

Figure 2
Dillon Communicator
EDxtreme, EDjr, and Communicator Service Manual 13
Communicator Keys The Communicator has the same keys as the EDX but also some extra
ones. They are all explained below:

On/Off key Use this key to turn the unit on and off.
Also, when in Radio Mode, this key will
access a menu for further options.

If you press and hold the

ZERO key for five seconds, the
ZERO key Use this key to zero the force indicated on
Communicator will reset the
the EDX and Communicator displays.
active EDX to the zero refer-
ence calibration point.
ESC key Use this key to escape from portions of
the menu structure and return to previous
choices or displays.

Arrow key Use this key to access any available soft

keys not currently viewed.

Up and Use these arrow keys to move through

Down key menu choices, when applicable. Also
scrolls through any active links.

Remote Use this key to access the Setup menu.

Setup key

Display Use this key to cycle between

Mode key Communicator display modes. They are
EDX specific force value, EDX specific
peak value, multiple display of force
values and multiple display of peak
values.

Keypad keys Use these keys to

enter numeric
characters. Use for
address assign-
ments and other
miscellaneous data
entry.

The Communicator may have between 2-3 connectors. CELL is for wireline
Communicator communications with an EDxtreme. COM1 is for serial communications.
Connectors AUX is not presently used and is either nonfunctional or not installed.

14 EDxtreme, EDjr, and Communicator Service Manual

Power On and Annunciators
When you power up the EDX you will see a display similar to the example
shown on the left in Figure 3.

Figure 3
Initial displays

The display sample above shows several symbols you may see on your
display but usually not all at the same time.
Force. This tells you that the display is showing live force measurement
at the moment. Will show Peak when viewing Peak Mode.
lbf Current unit of measure is lbf in this example. May also be kgf,
N, or up to 2 other custom units.
~ Motion symbol. This appears when the force is in motion. This
symbol disappears when motion ceases.
(Y) Antenna symbol. This shows you that the radio is enabled and
functioning.
Y The battery in the device is low and the radio section has been
turned off. The device will continue to display (EDX will display
force applied and Communicator will display dashes) but will be
unable to communicate by radio or, EDX or the Communicator
are improperly configured for RF communications on Comm port
#2 with no RF PC board installed.
(Y) (Y) 2 Ys indicate the Communicator is in communications with an
active EDX.
Battery annunciator. This shows approximate remaining battery
life.
Capture of a new peak value. This annunciator will remain lit for
Arrow key P
a few seconds.

Press the Arrow key to move between the two displays in Figure 3. In the
display on the right in Figure 3, one of the soft keys is labeled Setup. Press
this and you gain access to the soft keys shown in the Setup Menu in Figure
4.

EDxtreme, EDjr, and Communicator Service Manual 15

EDjr Introduction
The EDjuniorTM (EDjr) electronic dynamometer from Dillon is a force mea-
surement load sensor and digital readout in one instrument. The EDjr can be
used to measure tension or weight.
This section of the manual covers the description of the EDjr.
Be sure to read the safety precautions found in the Safe Operation section.

If you overload this dynamom-

eter you could suffer severe
injuries or death. The total load
on the dynamometer should
NEVER exceed the rated
capacity.

EDjr Description
The EDjr comes in several weight capacities. All have the same front panel,
EDjr Front Panel shown in Figure 3.

Figure 3
EDjunior front panel

There are four “hard” keys and four “soft” keys. The hard keys are perma-
nently labeled and the soft keys are just below the display. The soft key
EDjr Keys functions change and the key label appears above each key on the display.
Sometimes the individual soft keys are referred to as the F1, F2, F3 and
F4 keys as numbered from left to right.

16 EDxtreme, EDjr, and Communicator Service Manual

 On/Off key Use this key to turn the unit on and off.

If lift hardware (shackles,

chains, beams, hoppers, etc.) ZERO key Use this key to zero the force indicated
is used to support the load and on the display.
zeroed prior to lifting the
current load being displayed,
you can press the ZERO key ESC key Use this key to escape from portions of
for five seconds, the display the menu structure and return to previ-
will show the total load being ous choices or displays.
lifted based on the zero point
used in calibrating the EDjr.
Arrow key Use this key to access any available soft
keys not currently viewed.

EDxtreme, EDjr, and Communicator Service Manual 17

Power On and Annunciators
When you power up the EDjr you will see a display similar to the example
shown on the left in Figure 4.

Depending on permission
settings and/or revision of
firmware, various soft keys
may be in a different location or
not visible.

Figure 4
Initial displays

The display sample above shows several symbols you may see on your
display but usually not all at the same time.
Force This tells you that the display is showing live force measurement
at the moment. Will show Peak when viewing Peak Mode.
lbf Current unit of measure is lbf in this example. May also be kgf,
or N.
~ Motion symbol. This appears when the force is in motion. This
symbol disappears when motion ceases.
Battery annunciator. This shows approximate remaining battery
life.
Capture of a new peak value. This annunciator will remain lit for
P a few seconds.

18 EDxtreme, EDjr, and Communicator Service Manual

EDxtreme Calibration Menu

Figure 5 shows the calibration menu.

Calibration must be done using

applied loads to full capacity.

Figure 5
Calibration Menu

Setup Moves from calibration menu to setup menu. Refer to the User
Manual.
Super Moves from the calibration menu to the configuration menu.
Refer to the User Manual.
Calib Select calibration units. Add or modify calibration points.
ClrCal Clears all calibration points.
O.Load Overload counter. Device has exceeded 105% of rated capacity.
Capac Enter capacity of electronic dynamometer. Capacity should never
be altered from the front panel.
Serial Allows you to enter serial number and electronics revision. These
are viewable from the about menu in setup. This will not change
the factory stored serial numbers.
ROM Used for software updates.

EDxtreme, EDjr, and Communicator Service Manual 19

Calib. softkey Using the Calib soft key will enable you to do a field calibration of the
EDXtreme using applied load or dead weights. When you press the softkey,
the following is displayed:

Choose the unit of measure you will use to calibrate the unit; Pounds of
force (Ibf) or Kilograms of force (Kgf). Use the Sel softkeys to select your
desired unit for calibration and press the ENTER soft key.
You will see the calibration screen shown in Figure 6.

Figure 6
No load applied

Calib. Display Definitions Point: Refers to the calibration point. The EDXtreme offers 10
individual calibration points. This will allow you to make
adjustments to linearity if it is needed. Pressing the next
key will move you to the next calibration point.
Live Counts: Refers to the analog to digital (A to D) counts. This is a
value you will see change as load is applied.
Stored Counts: The A to D counts stored in memory for a calibration
point. This is the number of A to D counts the link uses
as a reference to a specified load. These counts will be
stored to memory when the set softkey is pressed.
Actual Ibf: This could be “Actual Kgf’ if the calibration unit was set
as Kgf. Refers to the amount of force or load applied
during the calibration procedure. This value will be
entered through the keypad when the set softkey is
pressed.

20 EDxtreme, EDjr, and Communicator Service Manual

Calib. Softkeys Next: This softkey will scroll to the next calibration point. There are a
total of 10 possible calibration points. Pressing next at number
10 will return you to calibration point number one.
Set: Calibration using dead weights or applied load. When you press
the set softkey, you will be prompted for an actual weight value.
If a KeyIn calibration is per-
You key in the amount of weight or load. The link will capture and
formed, the dynamometer must
average the A to D counts. This average will then become the
be checked using live weight or
value for the stored counts.
applied force.
Keyln: Calibration without using dead weight or applied load. This will
only work if you have previously saved calibration information.
Pressing the Keyln softkey will prompt you for “scale cnts”. You
manually enter the stored count reading from a previous calibra-
tion. Press the enter softkey. You will then be prompted for
“Actual Wt:”. Key in the weight reading from the previous calibra-
tion and press the enter softkey. The value will be displayed as
your stored counts and actual weight.
Clear: This softkey will clear calibration information, for that calibration
point, from memory. After pressing the softkey you will be asked
“Are you sure?” and prompted yes or no. Caution: If you select
yes, calibration data will be lost. The calibration point will need to
be recalibrated using Keyln, dead weight, or applied load.

Use the right arrow key to scroll through available calibration

points.

Press the ESC key to exit calibration.

EDxtreme, EDjr, and Communicator Service Manual 21

ClrCal softkey Press this softkey to delete ALL calibration information from memory. You
will be prompted Clear Cal? YES or NO.
Caution: If you select YES, all calibration data will be lost. The calibra-
tion points will need to be recalibrated using Keyln, dead weight, or
applied load.

O.Load softkey This will show you the Over range counters. This means the link has been
overloaded a minimum of 105% of full capacity. This counter cannot be
cleared or changed. Overloading of the link can cause damage to the link.

Capac softkey This softkey will allow you to enter the capacity of the Electronic Dynamom-
eter. Do not use any capacity other than the one shown on the back of the
dynamometer. See photo below:

Allows you to enter in user viewable information. This information is viewable

Serial softkey in the Setup About menu. This will not change the factory stored serial
number.

This softkey will allow you to do software flash upgrades in the field. (Under
ROM softkey development)

Using the ROM softkey will

delete all information and
software in the device.

22 EDxtreme, EDjr, and Communicator Service Manual

Communicator Calibration Menu
Figure 7 shows the Communicator’s calibration menu.

Figure 7
Communicator Calibration Menu

Setup Moves from calibration menu to setup menu. Refer to the User
Manual.
Super Moves from the calibration menu to the configuration menu.
Refer to the User Manual.
Serial Allows you to enter serial number and electronics revision.
These are viewable from the about menu in setup. This does
not change the factory stored serial number.
ROM Used for software updates.

Calibration Procedure for EDX and EDJr.

Before you begin make sure you have certified test weights or a certified test
Using Applied Load stand capable of applying full capacity to the link. Calibration should be done
in enhanced resolution mode (optional). Dillon recommends a minimum of a
five-point calibration.
Link power should be off.
l. Insert link into test apparatus using the shackles and pins with which it
will be shipped (when possible).
2. Apply 105% (+10% / -0%) three times, completely removing weight
between loadings. See table below for values.
3. With no load on the link, push I/O button to turn link power on.
4. For EDJr., skip to step 13.
For EDX, push the right arrow key and continue with step 6.
5. Push the Config soft key.
6. Push the Enter soft key.
7. Push the Reso soft key.
8. Push the Select soft key until Enhanced is displayed.
9. Push the Enter soft key.
10. Push ESC.
11. Push the Yes soft key and wait while changes are saved.
12. Push the right arrow key .
EDxtreme, EDjr, and Communicator Service Manual 23
 13. Push the Config soft key.
14. Key in the password 801 by using the Num , Num , and Adv soft
keys. Push the Enter soft key. Push the right arrow key w.
15. Push the Capac. soft key.
16. Key in the appropriate capacity by using the Num , Num , and Adv
soft keys. Push the Enter soft key.
17. Push Esc.
18. Push the Yes soft key.
19. Push the right arrow key .
20. Push the Config soft key.
21. Key in the password 801 by using the Num , Num , and Adv soft
keys. Push the Enter soft key.
22. Push the Calib soft key and then the Enter soft key, which takes you to
the Point 1 calibration screen.
23. Push the Set soft key.
24. Make sure no load is on the link, key in 0 if it is not the default, and then
push the Enter key to accept. Do not touch link until Point 1 calibration
screen reappears.
25. Push the Next soft key.
26. Apply the next load to be calibrated. See the chart in Table 1.
27. Push the Set soft key.
28. Key in the target weight using the Num , Num , and Adv soft keys.
Adjust the applied load until it matches the target value. Push the Enter
soft key. Do not touch link until the point calibration screen reappears.
29. If additional calibration points need to be entered, go back to step 25. If
not, continue on to step 30.
30. Push the Esc key twice.
31. Push the Yes soft key, which puts you into normal weighing mode.
32. Remove the load from the link.
If during steps 34 through 38, the link reading differs from the reference cell
by more than the tolerance shown in the table, stop immediately and return
to step 19 to re-calibrate.
If the link is out of tolerance at the same load value again after re-calibration,
return to step 19 to recalibrate but also add an additional calibration point at
the failing load value.
33. Push the Zero key and also zero the reference load cell indicator if
necessary.
34. Apply 20% of capacity and record link reading.
35. Apply 40% of capacity and record link reading.
36. Apply 60% of capacity and record link reading.
37. Apply 80% of capacity and record link reading.
38. Apply 100% of capacity and record link reading.

24 EDxtreme, EDjr, and Communicator Service Manual

 39. Repeat steps 34 through 38 three times
40. Remove the load from the link.
41. If all load points are within acceptable tolerances for all necessary
verification runs, remove link from test apparatus.
42. For EDJr., skip to step 50. For EDX, push the right arrow key and
continue with step 43.
43. Push the Config soft key.
44. Push the Enter soft key.
45. Push the Reso soft key.
46. Push the Select soft key until Standard is displayed.
47. Push the Enter soft key.
48. Push ESC.
49. Push the Yes soft key and wait while changes are saved.
50. Push the I/O key to turn off power.

Capacity 20% 40% 60% 80% 100% 105%

500 100 200 300 400 500 525
1,000 200 400 600 800 1000 1050
2,500 500 1000 1500 2000 2500 2625
5,000 1000 2000 3000 4000 5000 5250
10,000 2000 4000 6000 8000 10000 10500
25,000 5000 10000 15000 20000 25000 26250
50,000 10000 20000 30000 40000 50000 52500
100,000 20000 40000 60000 80000 100000 105000
160,000 32000 64000 96000 128000 160000 168000
220,000 44000 88000 132000 176000 220000 231000
330,000 66000 132000 198000 264000 330000 346500
500,000 100000 200000 300000 400000 500000 525000

Table 1

EDxtreme, EDjr, and Communicator Service Manual 25

Using Key-In Values Before you begin. You must have a print out or a list of previous calibration
points. This list needs to include both the applied load and stored counts for
that load. This list can be obtained from the dynamometer’s SETUP menu.

This will require you to have the link connected to a computer or a printer.
You will need the RS-232 cable (P/N - 36057-0022MTS) and have com2 set
up for RS-232 communication (reference user manual).
1. Turn link on.
2. Push the right arrow key .
3. Push the Config soft key.
4. Key in the password 801 by using the Num , Num , and Adv soft
keys. Push the Enter soft key.
5. Push the right arrow key .
6. Push the Capac soft key.
7. Key in the appropriate capacity by using the Num , Num , and Adv
soft keys. Push the Enter soft key.
8. Push Esc.
9. Push the Yes soft key.
10. Push the right arrow key .
11. Push the Config soft key.
12. Key in the password 801 by using the Num , Num , and Adv soft
keys. Push the Enter soft key.
13. Push the Calib soft key and then the Enter soft key, which takes you to
the Point 1 calibration screen.
14. Press the Keyln soft key.
15. Key in stored counts, by using the Num , Num , and Adv soft keys,
for the selected point. Press Enter to accept.
16. Key in actual weight, by using the Num , Num , and Adv soft keys,
for the selected point. Press Enter to accept.
17. Press the Next soft key to advance to the next point.
18. Repeat steps 14-17 until all points are keyed in.
19. When finished. Press Esc twice.
20. Press the Yes softkey.
21. Known weight must be applied to verify the calibration. If the link is out
of specification, listed in Table 1, an applied load calibration must be
done.

26 EDxtreme, EDjr, and Communicator Service Manual

Testing and Troubleshooting
Did the customer forget or lose the password? To reset the configuration
Resetting Configuration menu password, key in 80571. This will reset configuration password to the
Password standard default of 0. A new password can then be entered, if desired. This
code will not grant access to any distributor function.

Remove back of link or communicator. Remove jumper P9. Wait five

Download Failure minutes then try downloading again with the jumper removed. Do not forget
to reinstall the jumper or the dynamometer will not function properly. If
download still does not work return to Dillon Factory Service for repair.

1. Turn the unit on.

Keypad Test
2. Press the key.
3. Press the Setup soft key.
4. Press the Test soft key.
5. Press the Keys soft key.
6. Press each key, skipping the ESC key, on the keypad and confirm that
the Key Pressed: line is updated to show the key being pressed.
Include all the soft keys F1 through F4 and the hard keys Zero, On/Off,
and the numerical keys in the case of a Communicator.
7. When all keys have been tested press the ESC key three times to return
to the normal display
If any key fails replace the keypad/Backer plate assembly.

.
1. Connect a RS-485 cable from the communicator to the link.
EDx and Communicator
2. Configure the EDx to communicate via wireline.
Wireline Testing
Press the key and then press the Config softkey.
Press the Enter softkey.
Press the Comm softkey.
Press the COM2 softkey.
Press the Enter softkey three times.
Using the Sel Sel keys set the Trans Level: to RS485.
Press the Enter softkey.
Using the Sel Sel keys set the Mode: to Remote.
Press the Enter key twice.
Press the ESC key twice.
Press the Yes softkey.

EDxtreme, EDjr, and Communicator Service Manual 27

 3. Configure the Communicator to communicate via wireline.
Press the key and then press the Config softkey.
Press the Enter softkey.
Press the Comm softkey.
Press the COM2 softkey.
Press the Enter softkey three times.
Using the Sel Sel keys set the Trans Level: to RS485.
Press the Enter softkey.
Press the ESC key twice.
Press the Yes softkey.
4. Confirm that the Communicator is displaying the same reading as the
EDx.
5. Remove the 485 cable.

1. Configure the Communicator for wireless communication.

EDx and Communicator
RF testing 2. Press the key.

(for systems equipped 3. Press the Config soft key.

with radio) 4. Press the Enter soft key.
5. Press the Comm soft key.
6. Press the COM 2 soft key.
7. Press the Enter soft key three times.
8. Set the Trans Level: to RF using the Sel Sel then press the Enter
soft key.
9. For Communicator systems set the Radio Channel(1-64): to 3 and press
Enter three times. For Edx systems press the Enter soft key twice and
then set the Radio Channel(1-64): to 10 and press the Enter soft key.
10. Press the ESC key twice.
11. Press the Yes soft key.
12. Wait for the unit to restart and confirm that it will communicate to the
test fixture for a 1 minute duration, represented by a solid ( ). In the case
where a test fixture is not used set the radio channel to the same
number, (e.g. 1), and confirm that the units will communicate to each
other.

28 EDxtreme, EDjr, and Communicator Service Manual

Keypad Continuity Test Keypad not connected to the link. With Ohmmeter attached, press indicated
key for continuity.
for Link Only
I/O key Connect Ohmmeter between pins 11 and 2. Press I/O key.
ESC key Connect Ohmmeter between pins 5 and 12. Press ESC key.
F1 key Connect Ohmmeter between pins 11 and 3. Press F1 key.
F2 key Connect Ohmmeter between pins 13 and 3. Press F2 key.
F3 key Connect Ohmmeter between pins 2 and 3. Press F3 key.
F4 key Connect Ohmmeter between pins 12 and 4. Press F4 key.
key Connect Ohmmeter between pins 11 and 5. Press key.
ZERO key Connect Ohmmeter between pins 2 and 12. Press ZERO key.

Problem Possible Cause Check

Momentary power on Low Battery Replace batteries with high quality alkaline
and then shuts off batteries.
Does not power on Low Battery Replace batteries with high quality alkaline
batteries.
Batteries installed backwards. Insure positive battery terminals face inward
away from the battery cap.
No spring contact. Verify spring is installed into battery cap.
Software Reset Remove battery cap and reinstall after one
minute.
Display contrast too light Hold Right Arrow key down while pressing
the F2 key several times to increase the
display contrast.
Defective keypad button Perform keypad continuity test.
Display too dark Display contrast to dark Hold Right Arrow key down while pressing
the F1 key several times to decrease the
display contrast.
Inaccurate readings Compare against a reference load Place dynamometer in standard resolution.
Apply a known load or weight. Verify last
calibration.
Check repeatability Place EDX in low-resolution mode. Lift an
arbitrary weight several times as close to
capacity as possible. Record each weight
reading. Do the readings differ from each
other? Calculate the standard deviation of the
readings using a spreadsheet such as
Microsoft Excel. See if the deviation is greater
than 0.1% of the instrument capacity.
Local gravitational variances Compare readings against dead weight. May
be necessary to apply a custom unit of
measure or to recalibrate the dynamometer
on site.
Shackles and hardware Check all hardware for proper lubrication (if
bearing equipped). Check for wear or debris
on shackles, shack pins and bearings. Verify
that force is applied directly through the
dynamometer. Make sure there are no off
center or torsional loads.

EDxtreme, EDjr, and Communicator Service Manual 29

Problem Possible Cause Check
Radio Communication Low batteries Replace batteries with high quality alkaline
intermittent batteries.
Location close to ground or other Raise dynamometer remote high from ground
radio absorber. or floor and move away from walls, glass or
other obstructions.
Excessive distance or radio dead Bring link and communicator closer. Allow a
zone few seconds to reestablish communications.
Excessive radio noise or environment. Remove link and communicator from area to
a known good area of communications. If
system works fine in different environment,
there is interference in the original environ-
ment. This can be identified by systematically
shutting off potentially interfering devices and
monitoring EDx and Communicator perfor-
mance.
No radio communica- Low batteries Replace batteries with high quality alkaline
tions batteries.
Location close to ground or other Raise dynamometer remote high from ground
radio absorber. or floor and move away from walls, glass or
other obstructions.
Excessive radio noise or environment. Remove link and communicator from area to
a known good area of communications. If
system works fine in different environment,
there is interference in the original environ-
ment. This can be identified by systematically
shutting off potentially interfering devices and
monitoring EDx and Communicator perfor-
mance.
Radio configuration Check radio configuration. See user manual.
Damaged or disconnected hardware Configure a different link or communicator to
isolate which radio board is damaged or
disconnected.
Display changes to Low batteries Replace batteries with high quality alkaline
dashes batteries.
Intermittent or lost radio Perform radio troubleshooting and testing.
communications
Display changes to Overload condition Check for a deadload shift or O.Load counter
dashes has incremented. Inspect for physical damage
to link. Recalibrate and verify.
Batteries discharge High power drain options operating Disable or reduce backlight. Disable RS-232.
quickly Disable radio if not in use.
Low quality batteries or use of Use quality alkaline batteries such as Duracell
rechargeables copper-top or Energizer. Rechargeable
batteries do not attain the same usage hours
as high quality alkalines.
Custom units not Communicator not configured Configure communicator with same custom
available for custom units. units as EDX.

30 EDxtreme, EDjr, and Communicator Service Manual

 Standard deviation calculation
Helpful Hints

S = standard deviation
X = Actual reading
M = Mean or average of all readings
N = Total number of readings being summed.

Weighing and Force Measurement Practice

The basis for all electronic force measurement or weighing is measurement
of stress in a loadcell body. To obtain optimal results it is necessary to
establish a few basic rules, otherwise the effect may be a nonlinear or non-
repeatable response. Read and follow these tips and see the illustrations on
the next page.

For accurate performance the force acting on

Load Centering the unit must be in line with the unit. Center-
ing the load is accomplished by using the
shims on each side of the load cell so that it
is centered on the shackle pin. See the
illustration at right. The 50,000 lbf (20000 kgf)
and higher EDxtremes also include spacers
supplied with shackles.

Insure shackles are oriented parallel with the

Alignment instrument. Apply load in the center of the
shackle bow.

A proper fitting pin is important in order to

Proper Pin Fit generate an even stress distribution and
avoid yield stresses. To achieve published
accuracy you must use the shackle pins and
centering spacers provided by Dillon.

Torque and bending should be avoided. Use

Torque and Bending swivels on the lifting wire for anti-torque and
avoid side forces.

Certified shackles and lifting gear should

Certified Gear always be used in accordance to local laws
and federal legislation. Insure all hardware,
fittings and line used to sustain the load are properly sized and rated for the
installation. Have the system evaluated by a qualified engineer if any ques-
tion or uncertainty exists.

EDxtreme, EDjr, and Communicator Service Manual 31

Calculating Tension in a System

The setup shown above will give you an approximate tension reading. This
can vary from actual tension due to variables in equipment and environment.

32 EDxtreme, EDjr, and Communicator Service Manual

Good Force Measurement Practice

EDxtreme, EDjr, and Communicator Service Manual 33

EDX, EDjr Disassembly Procedures
1. Place dynamometer on a flat surface with the front side down.
Separating the link from
the electronics 2. Remove four screws from back panel.
3. Lift and remove back panel. For the EDXtreme you must disconnect
serial port wiring from connector P6 and the antenna cable from the
radio board (if installed).
4. Disconnect battery power wiring connector from P1. Disconnect the link
load cell wiring from P3 connector. Lift link and gently push the main PC
board / keypad assembly out the front of the link.

1. Remove two screws from the edge of the radio. Lift and rotate towards
Removing the radio the two white plastic standoffs to disconnect.
from EDXtreme main PC
board (if installed)

1. EDXtreme with backlight only. Gently spread the black connector while
Removing the main PC pulling away from the backlight LED. See Caution at left.
board from the keypad/
2. Disconnect the keypad ribbon cable from J3. See Figure 8. Gently pull
backer assembly the brown connector away from the main PC board and lift up. The
connector is hinged and requires rotation to release the ribbon cable.
Remove keypad ribbon cable from connector J3.

Be sure the backlight has been

turned off and cooled for 15
minutes prior to disassembly.
Do not look directly at LED
while in operation.

Figure 8
Removing cable from J3

34 EDxtreme, EDjr, and Communicator Service Manual

 3. Remove two screws located between P1 power connector and P3 load
cell connector. Remove two screws (2-56 x .25 standoffs if radio in-
stalled) from above and below J3 keypad connector.
4. Gently lift and rotate the main PC board off keypad/ backer assembly.
Rotate in the direction of J2 radio connector. While pressing LCD
display ribbon to the keypad/ backer assembly. Slowly rock and pull the
main PC board to release ribbon cable from connector. See Caution at
left.
LCD display ribbon cable is
built into the LCD display and
can be damaged easily.

Figure 9
Removing cable from J3

EDX, EDjr Reassembly Procedures

1. Connect LCD display ribbon cable to J1 on main PC board. See Figure
Main PC board to key- 10. Press the ribbon cable to keypad/ backer assembly and gently rock
pad/ backer assembly main PC board while pushing towards the LCD display ribbon cable.
Caution: LCD display ribbon cable is built into the LCD display and can
be damaged easily. See Caution at left.

LCD display ribbon cable is

built into the LCD display and
can be damaged easily.

The LCD ribbon cable connec-

tions are very small. Misalign- Figure 10
ment may cause display not to Connecting LCD display
function. Verify connections if
display does not power up.
2. Route keypad ribbon cable across LCD display.
3. Rotate main PC board onto keypad/ backer assembly. Install two
screws between P3 load cell connector and P1 power connector. Install
two screws (standoffs if using radio option in the EDXtreme only) above
and below J3 keypad connector. DO NOT TIGHTEN.

EDxtreme, EDjr, and Communicator Service Manual 35

 4. All screws or standoffs need to be tightened snuggly and in order to
prevent damage to the electronics.

2 4

3 1

Tightening sequence for main PC board

5. Connect keypad ribbon cable to J3. Insert ribbon cable, press towards
the main PC board and push to lock.
6. Connect backlight fiber optics to LED on main PC board (if backlight
installed).

36 EDxtreme, EDjr, and Communicator Service Manual

Radio installation or 1. If installing the radio field installation kit. Loosen all screws. Remove
two screws above and below the J3 keypad connection. Install two 2-56
upgrade EDXtreme only X .25 standoffs in place of screws. Tighten all screws in order (See
tightening sequence diagram).
2. Install white plastic standoffs in main PC board.

2 4

Plastic Plastic
standoff standoff

3 1

3. Align radio pins with radio connector J2. Align plastic standoffs with
radio. Press firmly to snap into place. Install screws and tighten snuggly.
4. Attach the antenna to the rear panel by attaching the double sided tape
to the back panel and adhering the antenna to the tape. See Figure 11.
5. Connect the antenna coaxial cable to antenna and radio board, as
shown in Figure 11

antenna
cable
rear panel

double sided tape

Figure 11
Connecting the antenna

EDxtreme, EDjr, and Communicator Service Manual 37

 1. With the link facing you, install the keypad/ main PC board assembly
Electronics installed into link fiber optics side first. Be sure not to damage the fiber optics.
into link Gently press the assembly until gasket seats.
2. Install power connector into P1 of main PC board. Install link connector
into P3 load cell connector.
3. On EDJr., install back panel.
4. For EDXtreme, align back panel link. Connect serial cable wiring to P6
serial connection on main PC board. If radio option is present or being
installed. Verify that the antenna is adhered to the back panel with
double sided tape. Connect antenna cable to radio and verify connection
to antenna.
5. Place back panel into position and verify that wiring is not pinched
between link and gasket.
6. Insert four screws and tighten snuggly.

38 EDxtreme, EDjr, and Communicator Service Manual

EDxtreme, EDjr, and Communicator Service Manual 39
 DILLON EDxtreme DYNAMOMETER
PARTS AND ASSEMBLY

ITEM
NO. DESCRIPTION W-T P/N QTY
1a Keypad/Backer Assy w/Display; incl: basic assy,
display restraint plate (item 7), 2 foam spacers (item
4), 4-.25”L standoffs (item 24), LCD display (item 3) 36249-0013 1
1b Keypad/Backer Assy w/ Display & Back Light; incl:
all above (uses qty. of “1” for foam spacers, item 4)
and fiber optic back light (item 6) 36250-0019 1
2 Standoff, m/f #4-40 x .25”L 15437-0183 4
3 LCD Display (ref: front. panl’s) 1
4 Spacer, foam (ref: front. panl’s) 2-max.
5 EDxtreme Main Board Assembly 36145-0018 1
6 Fiber Optic Backlight (ref: front. panl’s) 1
7 Display Restraint Plate (ref: front. panl’s) 1
8 Foam Gasket, (incl.w/front panel & rear cover assy’s) 36160-0018 1 ea. assy
9 Basic Rear Cover Assy, incl: lexan rear cover,
EDxtreme decal, foam gasket (item 8) 36253-0016 1
9a Rear Cover Assy w/Serial Connector, incl: basic
assy, serial connector assy (item 31) 36254-0015 1
9b Rear Cover Assy w/ Serial conn. & Antenna, incl: all
above, plus; tape (item 29) & radio antenna (item 27) 36255-0014 1
10 Screw, #4-40 x .62”L 14473-0157 4
11 Load Link Strain Gauge Assy (500 lb) 36183-0011 1
Load Link Strain Gauge Assy (1,000 lb) 36181-0013 1
Load Link Strain Gauge Assy (2,500 lb) 36179-0017 1
Load Link Strain Gauge Assy (5,000 lb) 36157-0013 1
Load Link Strain Gauge Assy (10,000 lb) 36174-0012 1
Load Link Strain Gauge Assy (25,000 lb) 36171-0015 1
Load Link Strain Gauge Assy (50,000 lb) 36175-0011 1
Load Link Strain Gauge Assy (100,000 lb) 36177-0019 1
Load Link Strain Gauge Assy (250,000 lb) 36185-0019 1
Load Link Strain Gauge Assy (500,000 lb) 36187-0017 1
12 Batterys, C-Size Alkaline (included) 15554-1030 2
13 Battery Cap Spring 52725-0013 1
14 Battery Cap (500 lb - 5,000 lb capacities) 36162-0016 1
Battery Cap (10,000 lb & 25,000lb capacities) 36223-0013 1
Battery Cap (50,000 lb capacity) 36223-0021 1
Battery Cap (100,000 lb capacity) 36223-0039 1
Battery Cap (160,000 lb & 220,000 lb capacities) 36223-0047 1
Battery Cap (330,000 lb capacity) 36223-0054 1
Battery Cap (550,000 lb capacity) 36223-0062 1
15 O-Ring 18022-0170 1
16 Complete Shackle Assy (incl: clevis, bolt, jamnut,
and cotter pin)
Shackle Assembly (500 lb thru 5K lb) 30010-0013 2
Shackle Assembly (10k lb) 36256-0013 2
Part Numbers for the EDxtreme Shackle Spacer Kits Shackle Assembly (25k lb) 15426-0020 2
Shackle Assembly (50k lb) 15426-0038 2
Shackle Assembly (100k lb) 15426-0046 2
Spring Pin or Shackle Assembly (250k lb) 48635-0168 2
Shackle Assembly (500k lb) 48635-0176 2
Capacity Spacer P/N* Hex Head Screw P/N Qty per EDx
17 Shackle Spacer (50k cap. version only) (not shown) 36222-0014 2/shackle
50K 36222-0014 16179-0944 4 Shackle Spacer (100k cap. version only) (not shown) 36222-0022 2/shackle
100K 36222-0022 16179-1157 4 18 Spacer roll pin (50k cap. version only) (not shown) 16179-0944 2/shackle
160K 36222-0048 16179-1157 4 Spacer roll pin (100k cap. version only) (not shown) 16179-1157 2/shackle

220K 36279-0016 17704-5770 4 19-22 -------NO PART------- ----- -----

330K 36269-0018 17704-5861 4 23 Screw, #2 x .19”L 14473-0017 4
550K 36301-0018 17704-6166 4 24 Standoff, m/f #2 x .19”L 15437-0019 6
* Must order both Spacer and Pins/Screw
(-parts list continued next page-)

40
 DILLON EDxtreme DYNAMOMETER
PARTS AND ASSEMBLY (-continued from previous page-)

Keypad/Backer Assembly (item 1, 1a or 1b) Replacement Procedure

To re-assemble the keypad assembly (including any optional items) and the rear
cover into load link unit, refer to “Front Panel/Rear cover Internal Parts Assy Detail”
or “Wiring/Connection Detail” or “Radio Board Detail” in the “EDxtreme” section of
ITEM this manual , and the following notes:
NO. DESCRIPTION W-T P/N QTY 1. Place Display bd. (item 3) into Keypad/Backer assy. Center the Backlight
(item 6) and one Foam Spacer, (item 4), (or 2 foam spacers, if you don’t have
25 Nylon PC Board Support Spacer 52590-0031 2
Backlight option) over Display. Then attach Restraint Plate (item 7) to Keypad
26 Radio Board (optional) 48686-1016 1 assy using the 4 standoffs (item 24).
27 Radio Antenna (optional, used w/ radio board oprion) 48686-0992 1 2. Insert the Display Bd. tail into J1 on main bd. (item 5). Route the Keypad tail
28 Radio Antenna Cable Assy (used w/ radio option) 36168-0010 1 as shown, then lower Main bd. into place. Attach Main bd. to Keypad assy
using 2-screws (item 23) and 2-standoffs (item 24) as shown. Insert Keypad
29 2-side sticky tape (for antenna option) 17822-0075 1 tail into J3 on Main bd.
30 LED lamp (ref: back light options) ------ 1
3. Insert the 2 Plastic Standoffs (item 25) into Main bd. Aligning all connector
31 Serial Connector/Cable Assy 36006-0032 1 pins, attach Radio Bd. (item 26) with matching connector J2 on Main bd.,
32 Screw, #4 x .19”L 14473-0090 1 press board into place, snapping onto the plastic standoffs.

--Items Not Shown-- 4. Insert Keypad/Backer Assy into recess in front side of Loadlink. Connect Link
strain gauge cable to P3, Power Cable to P1, Serial Cable to P6, Fiber Optic
33 Cable Assy, Communicator-to-EDxtreme 36057-0014 1
Backlight to DS1 on Main bd. and Radio Cable assy to Antenna and Radio
34 Cable Assy, Computer-to-EDxtreme 36057-0022 1 Board.
35 EDxtreme Carrying Cases:
2.5K/5K Capacity 36192-0010 5. Place Rear Panel assy into recess on backside of Link, making sure all wires
10K Capacity 36193-0019 are clear of “pinch points”, then install screws (item 10) and tighten firmly.
25K Capacity 36194-0018 CAUTION.....do not over tighten screws ! (torque to 4-6 in. lbs.)
50K Capacity 36195-0017
100K Capacity 36196-0016
--Field Install Kits--
EDxtreme Back Light Field Install Kit , incl: back
light option (item 1b) “plus” LED lamp (item 30) 36251-0018 1
EDxtreme Radio Field Install Kit , incl: radio board
(item 26), 2-spacers (item 25), 2-standoffs (item 24),
antenna (item 27), cable (item 28) & 2-side stk. tape 36252-0017 1
(must have “Rev. F” or newer firmware)

41
 DILLON EDxtreme DYNAMOMETER
KEYPAD/BACKER ASSY
and MAIN BOARD ASSY

42
 DILLON EDxtreme DYNAMOMETER
INTERFACE CABLE PIN-OUTS & EDx and
COMMUNICATOR AC POWER SUPPLY

AWT Wire Origin Dest.

Color Termination Termination Signal
J3-2 P1-1 Blk Tx/Rx
J3-3 P1-2 Wht Rx/Tx
Power Supply P1-3 Red VDC
J3-5 P1-4 Grn Signal Ground

EDx and Communicator

AC Power Supply

43
 DILLON EDjunior DYNAMOMETER
PARTS AND ASSEMBLY

ITEM
NO. DESCRIPTION W-T P/N QTY
1 Basic Keypad/Backer Assy; incl: kepad, lexan cover,
foam gasket (item 8) 36258-0011 1
1a Keypad/Backer Assy w/Display; incl: basic assy,
display restraint plate (item 7), 2 foam spacers (item
4), 4-.25”L standoffs (item 6), LCD display (item 3) 36259-0010 1
2 Standoff, m/f #4-40 x .25”L 15437-0183 4
3 LCD Display (ref: front. panl’s) 1
4 Spacer, foam (ref: front. panl’s) 2
5 EDjunior Main Board Assembly 36145-0026 1
6 Standoff, m/f #2 x .19”L 15437-0019 4
7 Display Restraint Plate (ref: front. panl’s) 1
8 Foam Gasket, (incl.w/front panel & rear cover assy’s) 36160-0018 1 ea. assy
9 Basic Rear Cover Assy, incl: lexan rear cover,
EDjunior decal, foam gasket (item 8) 36260-0017 1
10 Screw, #4-40 x .62”L 14473-0157 4
11 Load Link Strain Gauge Assy (500 lb) 36221-0015 1
Load Link Strain Gauge Assy (1,000 lb) 36221-0023 1
Load Link Strain Gauge Assy (2,500 lb) 36221-0031 1
Load Link Strain Gauge Assy (5,000 lb) 36221-0049 1
Load Link Strain Gauge Assy (10,000 lb) 36221-0056 1
12 Batterys, C-Size Alkaline (included) 15554-1030 2
13 Battery Cap Spring 52725-0013 1
14 Battery Cap (500 lb-5,000lb capacities) 36162-0016 1
Battery Cap (10,000 lb capacity) 36223-0013 1
15 O-Ring 18022-0170 1
16 Complete Shackle Assy (incl: clevis, bolt, jamnut,
and cotter pin)
Shackle Assembly (500 lb thru 2.5K lb) 15426-0103 2
Shackle Assembly (5k lb) 15426-0095 2
Shackle Assembly (10k lb) 15426-0012 2
17 Screw 2-56 x .19”L 14473-0017 4
18 Screw 4-40 x .19”L 14473-0090 1

44
 DILLON EDjunior DYNAMOMETER
PARTS AND ASSEMBLY (-continued from previous page-)

Keypad/Backer Assembly (item 1, 1a or 1b) Replacement Procedure

To re-assemble the keypad assembly (including any optional items) and the rear
cover into load link unit, refer to “Front Panel/Rear cover Internal Parts Assy Detail”
or “Wiring/Connection Detail” in the “EDjunior” section of this manual , and the
following notes:
1. Place Display bd. (item 3) into Keypad/Backer assy. Center the 2 foam
spacers, item 4, over Display. Then attach Restraint Plate (item 7) to Keypad
assy using the 4 standoffs (item 6).
2. Insert the Display Bd. tail into J1 on main bd. (item 5). Route the Keypad tail
as shown, then lower Main bd. into place. Attach Main bd. to Keypad assy
using 4-screws (item 17) as shown. Insert Keypad tail into J3 on Main bd.

3. Insert Keypad/Backer Assy into recess in front side of Loadlink. Connect Link
strain gauge cable to P3 and Power cable to P1 on Main bd.

4. Place Rear Panel assy into recess on backside of Link, making sure all wires
are clear of “pinch points”, then install screws (item 10) and tighten firmly.
CAUTION.....do not over tighten screws ! (torque to 4-6 in. lbs.)

45
 DILLON EDjunior DYNAMOMETER
KEYPAD/BACKER ASSY
and MAIN BOARD ASSY

46
 DILLON REMOTE COMMUNICATOR
PARTS AND ASSEMBLY

ITEM
NO. DESCRIPTION W-T P/N QTY
1 Serial Connector/Cable Assy 36006-0032 3

Note: 2 Enclosure 36154-0016 1

3 DC Power Cable Assy 36167-0011 1
Other than the illustration and the parts list shown
4 Antenna Cable Assy, used w/Radio Board (optional) 36168-0028 1
on this page, there are very few “field serviceable”
5 Dillon Communicator Decal 36199-0013 1
parts in the Communicator assembly. Main Board 6 Battery Cradle (includes screws) 46605-0036 1
and Keypad serviceing require the board to be 7 Battery Cable Terminals (complete set -of 5) 46605-0044 1 pkg.
unsoldered from the Keypad/Backer plate assembly. 8 Gasket Kit (incl: enclosure & battery cover gasket) 46605-0051 1
If repair is reqiuired in this area, the Communicator 9 Battery Door 46605-0093 1
needs to be returned to Dillon Factory Service for 10 Model Identification Label 36202-0026 1
11 Protective sleeve for Communucator (not shown) 46605-0077 1
repair or replacement.
12 Wall Holder Bracket (not shown) 46605-0069 1
13 Transceiver Radio Board (optional) 48686-1016 1
14 Hardware Kit (incl: 6-long & 4-short screws as shown) 46605-0085 1
15 Nylon PCB Spacer (used w/ Radio option) 52590-0013 4
16 Plastic Carry Case (not shown) 36197-0015 1
17 Battery, Alkaline AA-size 15554-1022 4
--Field Install Kit--
Radio Kit (incl: PC board., standoffs, antenna cable)
(must have “Rev. E” or newer firmware) 36257-0012 1

47
 Dillon
A division of Weigh-Tronix Inc.
1000 Armstrong Dr.
Fairmont, MN 56031 USA
Telephone: 507-238-4461
Facsimile: 507-238-8258
e-mail: dillon@weigh-tronix.com
www.dillon-force.com

October 2008 EDX_S.P65 PN 29809-0010 Issue AC Printed in USA Force Measurement Products & Systems