Rice Lake Loadrunner Dump Truck Systems Kit User Manual
™
LoadRunner
OnBoard Weighing System for Dump Trucks
Series
Installation & Service
Manual
162356 Rev A
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com/training
or obtained by calling 715-234-9171 and asking for the training department.
Contents
1.0 Introduction..................................................................................................................................... 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Considerations Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Welding Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Load Pin and Transducer Specification ......................................................................................... 3
2.1 Onboard Dump Truck Kit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Load Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 Roll Off Load Pin Installation .......................................................................................................... 5
3.1 Installing the Load Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Installing the Inclinometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Power Cable Connection to Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Hydraulic Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Routing Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Install the Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6.1 Electrical Wiring and Data Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.0 Configuration and Calibration ...................................................................................................... 13
4.1 User and Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Initial Setup of the OB-350 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 Initial Password Entry and Clock Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.2 Configuration of Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Configuration of Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Configuration of Zero Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Configuration of Inclinometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Configuration of Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7.1 Calculating the SPAN (Net Weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7.2 Enter Tare Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.7.3 Set Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.7.4 Full Span (Net Load) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.0 Service and Troubleshooting........................................................................................................ 20
5.1 System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Sensor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.1 Load Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.2 Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 Cables and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hardware Warranty Statement ................................................................................................................. 22
© Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Rice Lake Weighing Systems is an ISO 9001 registered company.
Specifications subject to change without notice.
Version 1.0, May 7, 2014
Contents i
ii LoadRunner™ Series Installation & Service Manual
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars.
1.0 Introduction
Important
CAUTION
WARNING
DANGER
WARNING
This manual is intended for use by technicians responsible for installing and servicing LoadRunner Series Onboard
Weighing Systems.
This manual contains instructions for i
systems). For straight trucks, this manual includes rigid under-body mounting instructions in four and six point
configurations, as well as under-body load pin installation instructions for tipping bodies and hoist chassis. Tipping
body installations can be either Lift-to-Weigh or Live-Weigh system types.
Authorized distributors and their employees can view or download this manual from the Rice Lake
Weighing Systems distributor site at
1. 1 S af et y
Safety Symbol Definitions:
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation that, if not avoided, could result in serious injury or death, and
includes hazards that are exposed when guards are removed.
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
nstalling various types of Onboard Weighing Systems (non Legal-for-Trade
www.ricelake.com.
Indicates information about procedures that, if not observed, could result in damage to equipment or
corruption to and loss of data.
General Safety
Do not operate or work on this equipment unless you have read and understand the instructions and
warnings in this manual. Failure to follow the instructions o
death. Contact any Rice Lake Weighing Systems dealer for replacement manuals.
Proper care is your responsibility.
Failure to heed may result in serious injury or death.
DO NOT allow minors (children) or inexperienced persons to operate this unit.
DO NOT operate without all shields and guards in place.
DO NOT jump on the scale.
DO NOT use for purposes other than weight taking.
DO NOT place fingers into slots or possible pinch points.
DO NOT use any load bearing component that is
DO NOT use this product if any of the
DO NOT exceed the rated load limit of the unit.
DO NOT make alterations or modifications to the unit.
DO NOT remove or obscure warning labels.
Keep hands, feet and loose clothing away from moving parts.
components are cracked.
worn beyond 5% of the original dimension.
r heed the warnings could result in injury or
Introduction 1
WARNING
1.2 Considerations Before Installation
Important
WARNING
Failure to observe these recommendations and instructions could result in a hazardous
operating condition.
This manual is intended to provide information for the mounting of Onboard Weighing Systems sensors in a
variety of applications. In applying the installation procedures, which follow, some fundamental precautions and
recommendations must be observed by the installer:
• Rice Lake Weighing Systems’ Onboard Scales are design
ed for applications covering a broad range of
vehicle types. Things to take into consideration are:
- Significant variations in mountings
- Variations in load sensor models
- Specifications
- System configurations
• Installation procedures are similar for both new vehicle mountings
and retro-fit mountings. When doing a
retro-fit mounting, ensure that all vehicle structures are free from cracks, excessive wear, corrosion,
alignment problems, etc. that could affect safety and scale performance.
• Load cells, load cell bearing plates, mounting brackets an
d load cell hardware should be painted upon
installation to help protect the installation from corrosion. Industry appropriate, quality enamel paint is
recommended.
- For environments where high concentrations of sa
lts are used on road surfaces, under-body coating is
recommended (3M™ Underseal™ part number 3M-8883 Universal Rubb erized Undercoating).
- Load cells, bearing plates, brackets and hardware shou
ld be periodically inspected for any evidence of
rust or corrosion. If areas of corrosion are present, they should be cleaned with a wire brush and
re-painted or undercoated.
- Load cell connectors must be connected or capped during painting or undercoating.
• The instructions outlined herein are designed to
ensure that a correct installation will provide maximum
safety, optimum system performance and accuracy, a long operating life, and reasonable installation costs. It
is required that the installer comply with all guidelines and material specifications outlined in this manual,
with special emphasis on detail and inspection of work.
• Installation must comply with appropriate
regulations of the U.S. Department of Transport ation (DOT), state
and local regulations, the recommended standards and practices of the Society of Automotive Engineers
(SAE), standards of the American W elding Society (AWS), and the recommendations of the truck, trailer and
body, hoist and/or suspension manufacturer.
1.2.1 Welding Specifications
Welding, metalworking and assembly shou ld only be performed by qualified personnel experienced in welding on
vehicle body structures and sub frames. Only welding equipment of the highest quality should be used in the
welding of load cell bearing plates. When welding, use procedures that ensure high quality welds. Over-welding
may result in distortion and damage, while under welding may not develop adequate strength.
Rice Lake Weighing Systems recommends removal of load cell after tack welding bearing plates in
position so that final welding is performed without load ce
current, or cable damage.
If welding with load cells in position, the installer must ensure that electrical current cannot flow through the load
cell. All load cell terminals must be shorted together. Attach the ground strap directly to the vehicle frame member
to which the bearing plates will be welded. Never weld directly to a load cell.
Always disconnect battery terminals before performing any welding.
2 LoadRunner™ Series Installation & Service Manual
ll being subjected to excessive heat, weld
2.0 Load Pin and Transducer Specification
Note
3
4
1
5
6
7
2
2
8
9
10
11
12
13
15
14
The Rice Lake Roll Off and Dump Truck kits are typically LIFT-TO-WEIGH KITS. This means that with the hoist
in the relaxed state (on the chassis), no weight reading is available. The hoist needs to be elevated to a position
showing the correct angle on the in-cab digital display unit, approximately four degrees, for the weight reading
degrees to be valid and accurate.
This manual provides instructions for the installation of straight frame dump trucks and “pup” dump trailers only.
For information on full frame or frame-less end dump or side du
Precision Loads manual (PN 115094).
2.1 Onboard Dump Truck Kit Parts
mp trailers, please refer to the Rice Lake
Figure 2-1. Onboard System – Dump Truck Kit Illustration
Item No. Part No. Description Qty
1 119966 Support, 1 x 4 x 5.16 1
2 119963 Ring, .25 x 2.25 x 3 4
3 131207 Pin, Load Dump Truck 2
4 119974 Glass Tubing 2
5 119973 Load Cell Mount Weldment 2
6 119969 Weldment, Support Ring 2
7 153117 Screw, Cap 1/2-20NF x 5” 2
8 Nut, Top Locking 2
9 131800 Cable Assembly 6’ 3
10 131226 Splitter, Cable Y-Splitter 1
11 131222 Inclinometer, Onboard 1
158196 Bracket, Onboard Inclinometer 1
12 131228 Cable Assembly 15’ (5M) 1
13 131200 Transducer, Hydraulic 1
14 131219 Indicator, OB3502 Channel 1
15 131221 Cable Assembly Fuse 1
Table 2-1. Onboard System – Dump Truck Kit Parts List
Load Pin and Transducer Specification 3
2.2 Load Pins
Electrical
Connector
Double shear load pin
made from heat treated alloy steel
nickel plated for corrosion resistance
fitted with an M12 commercial vehicle class connector
11.8" (300 mm)
2"
(49 mm)
0.79"
(20 mm)
5.5"
(142 mm)
0.79"
(20 mm)
0.5 Ø (14 mm )
Orientation and
Anti-rotation
Reaction
Force
Reaction Force
2.4"
(62 mm)
6.4"
(162 mm)
2"
(53 mm)
Chamfer
0.12"
(3 mm) x 45°
Both Ends
0.4"
(10 mm)
Ø 2" d10 Ø
50.70
50.58
Direction of Load
Direction
of Load
1.2" A/F
(30 mm)
0.25" (6 mm)
0.31"
(8 mm)
2" (50 mm)
1" Ø
(26 mm)
9/16
"-18 SAE
1.2" Ø
(33 mm)
16' (5 M) if four core cable
with a M12 fully moulded male connector
Material: Stainless Steel
Sealing: Fully welded to IP68
Hinge pivot and lift cylinder load pins built by Rice Lake Weighing Systems are available in two sizes:
• 2 inch diame ter (see Figure 2-2) Dump Truck
Full length hinge bars are also available a
Lake Weighing Systems dealer or the factory). All load pins are supplied with collars and bolts with locknuts to
secure pin position. The installer must ensure that all load pin installations can receive required initial and periodic
lubrication.
s direct replacements for tipping bodies with hinge bars (contact a Rice
2.3 Pressure Transducer
Figure 2-2. 2 Inch Diameter Load Pin (PN 131207)
Figure 2-3. Oil Pressure Transducer (PN 13 1211)
4 LoadRunner™ Series Installation & Service Manual
3.0 Roll Off Load Pin Installation
Important
Load Pin Kits
Inclinometer
Y Cable
Battery
Trans du ce r
Indicator
Power Cable
Homerun Cable
Note
All load pin installations require lubrication facilities. Normally lubrication is provided through the central
pivot area.
Lake pivots are furnished with drilled and tapped holes for the insertion of a standard lube zerk which
must be supplied and installed by the system installer.
3.1 Installing the Load Pins
1. Remove the rear fenders from the truck, if required, to gain free and clear access to the pivots.
2. Use jacks or a forklift to support the rear of the dump bucket
pivot pins are being replaced.
3. Remove the bolt and washer from the collar/support on the
Removing pivot pins on some vehicles may be difficult if rust is present or if the hoist chassis pivot and the truck
chassis supports are out of alignment. If rust is an issue,
tapping the pivot pin out. Use a pry bar as a lever to assist with any misalignment problems to remove the
existing pivot pins.
4. Push the pivot pins out of the supports.
5. Mark the frame where the pivot supports are located, in an area
frame smooth. This will assist in the location of the new supports.
6. Remove the supports from t
7. Using a power grinder or a wire brush, clean the area where the supports were
frame. Grind the frame smooth to ensure a clean weld for the support installation.
OEM Roll Off pivots typically have existing lubrication fittings included in their pivots. Rice
Figure 3-1. LoadRunner System Layout
and maintain its position/alignment while the
pivot.
use a penetrating lubricant and appropriate tools for
that will not be affected by grinding the
he frame of the truck.
located, both sides of the
Roll Off Load Pin Installation 5
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