Rice Lake SURVIVOR OTR User Manual
®
SURVIVOR OTR
Flattop Truck Scale
Assembly Instructions
53831 Rev D
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
2.0 Installation ................................................................................................................................... 2
2.1 Foundation Slab Cure Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Assembly Time Estimates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Recommended Equipment and Tools (Steel Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 Lifting and Handling (Steel Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Temporary Setting Blocks (Steel Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Recommended Equipment and Tools (Concrete Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Lifting and Handling (Concrete Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.8 Temporary Setting Blocks (Concrete Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Assemble Deck Modules ............................................................................................................. 6
3.1 Place End Module A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Place and Attach Adjoining Modules B and C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Raise Deck and Level with Approaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.0 Load Cell Mount Installation...................................................................................................... 10
4.1 Install Baseplate and Load Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Mount Block and Shim (Groutless) Installation (Option 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Mount Block and Grout Installation (Option 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0 Load Cell Wiring ........................................................................................................................ 16
6.0 Pour, Finish, and Cure Concrete Deck....................................................................................... 19
6.1 Concrete Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Pour and Finish Concrete Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3 Moist-Cure Concrete Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.0 Connecting Electronic Equipment ............................................................................................. 22
7.1 Indicator to Peripherals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.2 Single-Point Ground Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.3 J-box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.4 Electrical Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.5 Installing Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.0 Trimming and Calibration.......................................................................................................... 26
8.1 Overview and Equipment Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.2 Trimming Individual Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.3 Trimming Paired Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.4 Calibration with Test Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.5 Serial Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.0 Load Cell Replacement.............................................................................................................. 30
© 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 2.1, August 2014
i
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars.
Vehicle Scale Limited Warranty............................................................................................................ 31
For More Information ............................................................................................................................. 32
ii OTR Truck Scale Assembly Instructions
1.0 Introduction
Note
DANGER
WARNING
CAUTION
Important
WARNING
This manual is intended for use by technicians responsible for installing and servicing the SURVIVOR® OTR
series truck scale. The OTR truck scale is designed so that on-site installation time is reduced as much as poss ible.
A well-organized, experienced installation crew should be able to install a standard 70' x 11' OTR truck scale in
one day.
This booklet covers the OTR steel deck and concrete deck flattop truck scale installation procedures. Use
these instructions as general installation guidelines unless the engineering drawings furnished with your scale
differ from the instructions in this booklet. Engineering drawings furnished with your scale always take priority
over these general installation guidelines.
Refer to the engineering drawings furnished with the scale for all component numbering sequences.
Authorized distributors and their employees can view or download this manual from the Rice Lake
Weighing Systems distributor site at
Package includes: Assembled weighbridge modules and weighbridge fasteners; load cells; conduit fitting; load
cell mounts with leveling bolts and anchor bolts; copper transient bypass cables at each load cell; conduit for load
cell cable runs; flexible plastic conduit from load cell to metal conduit; conduit fittings from flex conduit to metal
conduit; Poly-carbonate junction box(es); homerun cable to indicator (60' long) and print packages including
foundation drawing (pier or floating slab) and manual.
Package does not include: Approach coping; foundation alignment posts; rebar and mesh for foundatio n; rebar for
deck; concrete; peripherals; freight charges including material handling/crane; transportation permits and fees,
escort(s) charge, and insurance transportation fees.
www.ricelake.com.
1. 1 S af e ty
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.
Indicates information about procedures that, if not observed, could result in damage to equipment or
corruption of 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 or heed the warnings could result in injury or
death. Contact Rice Lake Weighing Systems 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 use for purposes other than weight measurement.
DO NOT place fingers into slots or possible pinch points.
DO NOT use any load-bearing component that is worn beyond 5% of the original dimension.
DO NOT use this product if any of the components are cracked.
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.
Introduction 1
2.0 Installation
The modular sections of the OTR series truck scale are shipped pre-assembled and ready to be placed into position
on temporary setting blocks using a crane.
The deck modules are first connected and positioned on setting blocks. Next, the load cell mounts are installed and
anchored into final position.
Then, run the electrical wiring to the J-box through conduit. The weighbridge is lowered onto the load cell mounts.
All electronic equipment is then connected to finish the installation.
The general assembly order is summarized below:
1. Set deck modules into position on setting blocks.
2. Install load cell mounts in pockets and anchor bolts in baseplates.
3. Run cabling and connect electrical wiring to J-box.
4. Pour, finish, and seal (concrete deck).
5. Connect indicator and peripheral devices.
2.1 Foundation Slab Cure Period
Standard concrete reaches full strength after a 28-day curing period. At seven days, standard concrete reaches
approximately 75% of its maximum strength and can handle moderate loads.
Please refer to ACI318 for additional information regarding concrete curing requirements, and consult your
concrete vendor to discuss curing requirements based upon the mix used specifically for your site. Loading of a
slab before it reaches 75% of its maximum strength may cause permanent structural damage.
2.2 Assembly Time Estimates
When scheduling installation for a typical three-module, 70' truck scale, plan for a two-hour minimum crane rental
to place the modules into position. A two-man crew, aided by a crane operator, can unload modules from the truck
and place them into position in approximately 1 hour.
Mount and load cell installation will require approximately 3 – 4 hours. Electrical wiring is run through conduit
and can be done in approximately 2 – 3 hours.
For concrete deck scales, a concrete crew of three or four can normally pour, finish, and seal-cure the concrete deck
surface of a 70' scale in 2 – 3 hours. Final wiring connections can normally be completed the same day while the
concrete is curing. These estimated times may vary.
2.3 Recommended Equipment and Tools (Steel Deck)
• Crane with a minimum 8000 lb.* capacity
• Four chains or cables (8' minimum length each) with hooks or clevises
• 3/4" rotary hammer drill
• 3/4" x 24" masonry carbide bit
• One low-profile 4-ton bottle jack
• 5 1/2" setting blocks
• Various thickness shims to level scale
• Torque wrench to 100 ft-lb
• Socket wrenches to 1 1/2" (drive compatible with torque wrench)
• Box end wrenches to 1 1/4"
• Open end wrench set (7/16" – 1 1/4")
• 4' bubble level
• Small torpedo level
• Hammers, maul, pry bar
• Hand tools for pulling and connecting electrical wiring
* Typical single module weight of 70' x 11', three-module truck scale.
2 OTR Truck Scale Assembly Instructions
2.4 Lifting and Handling (Steel Deck)
DANGER
Note
7.5"
5 1/2"
12 1/4"
17 3/4"
1/4"
18"
Note
Deck modules are lifted (see Figure 2-1) using four chains or cables attached to the four lift lu gs mounted on the
top of the weighbridge. The lift lugs provide balanced lifting of the modules.
Figure 2-1. Lifting Deck Modules (Steel Deck)
Loads may disengage from crane scale hook and shackle or lifting eye if proper procedures are not
followed. A falling load may cause serious injury or death.
Never lift more than the crane scale’s assigned Working Load Limit (WLL) rating.
A set of lifting lugs are provided with the scale and shipped on the last module loaded on the truck at the
factory.
2.5 Temporary Setting Blocks (Steel Deck)
When the deck is level with the approaches, the finished scale has 5 3/4" clearance between the bottom of the
weighbridge and the concrete foundation. Most installers use setting blocks that are approximately
5 1/2" high for the initial placement and connecting of the deck modules. Shims are used to level the scale and raise
it flush with the approach bulkhead. Setting blocks are only used in the corners of the modules where the load cell
mounts are installed. The corners that do not have load cell mount locations do not require setting blocks.
Figure 2-2. Setting Block Measurements (Steel Deck)
Figure shown for 18" foundation profile.
When placing modules on setting blocks, place blocks in locations close to, but not at, the pocket (to allow
room for mount).
Installation 3
2.6 Recommended Equipment and Tools (Concrete Deck)
DANGER
• Crane with a minimum 7000 lb* capacity
• Four chains or cables (8' minimum length each) with hooks or clevises
• 3/4" rotary hammer drill
• 3/4" x 24" masonry carbide bit
• One low-profile 4-ton bottle jack (20-ton jack required after concrete pour)
• 5 1/2" setting blocks
• Various thickness shims to level scale
• Torque wrench to 100 ft-lb
• Socket wrenches to 1 1/2" (drive compatible with torque wrench)
• Box end wrenches to 1 1/4"
• Open end wrench set (7/16" – 1 1/4")
• 4' bubble level
• Small torpedo level
• Hammers, maul, pry bar
• Hand tools for pulling and connecting electrical wiring
• Concrete vibrator (optional)
• Concrete screed board, bull float, hand trowels, edger, and broom
• Long-handled paint roller or spray gun for applying epoxy curing agent
* Typical single module weight of 70' x 11', three-module truck scale.
2.7 L
ifting and Handling (Concrete Deck)
Concrete deck modules are lifted (see Figure 2-3) using four chains or cables attached to the four gussets mounted
on the inside of the main beams. The gussets provide balanced lifting of the modules.
Figure 2-3. Lifting Deck Modules (Concrete Deck)
Loads may disengage from crane scale hook and shackle or lifting eye if proper procedures are not
followed. A falling load may cause serious injury or death.
Never lift more than the crane scale’s assigned Working Load Limit (WLL) rating.
4 OTR Truck Scale Assembly Instructions
Following module final positioning, the gussets are no longer needed and are covered by the final concrete pour.
Note
Figure 2-4. Lifting Gusset
2.8 Tempo
rary Setting Blocks (Concrete Deck)
When the deck is level with the approaches, the finished scale has 5 7/8" clearance between the bottom of the
weighbridge and the concrete foundation. Most installers use setting blocks that are approximately 5 1/2" high
for the initial placement and connecting of the deck modules. Shims are used to level the scale and raise it flush
with the approach bulkhead. Setting blocks are only used in the corners of the modules where the load cell mounts
are installed. The corners that do not have load cell mount locations do not require setting blocks.
Figure 2-5. Setting Block Measurements (Concrete Deck).
Figure 2-5 shown for 18" foundation profile.
When placing modules on setting blocks, place blocks in locations close to but not at pocket (to allow room for
mount).
Installation 5
3.0 Assemble Deck Modules
Note
BA C
d d
Section dd
Module Support Pin
Pin Connection Receptacle
Concrete
Approach
Concrete
Approach
Deck modules are designated as A, B or C (see Figure 3-1). All two-module scales have an A and C module, while
longer scales with more than two modules have one or more B modules.
The modules are typically marked as A, B, or C on the end of each module for identification during placement
and assembly.
Figure 3-1. OTR Deck Modules
A Module
An A module is an end module and is the first to be placed on setting blocks. The left end is a straight end which is
positioned next to the vertical wall of the concrete approach (see Figure 3-1). The right end of the A modu le
contains two pin-connection receptacles that are used to accept the two module-support pins located on the B
module.
B Module
The B module is a center module and is similar in design to the A module, with the exception that it has two
module-support pins on the left end and two pin-connection receptacles on the right end (see Figure 3-1). The tw o
module-support pins of module B are inserted into the two pin-connection receptacles of module A. Also, the
pin-connection receptacles of module B accept the module-support pins from another B module or a C module.
C Module
The C module is also an end module and is the last one placed on setting blocks (see Figure 3-1). The two
module-support pins are designed to attach to either an A module for a two-module installation or to a B module
for an installation that has more than two modules. The opposite end of the C module is a straight end and is
positioned next to the vertical wall of the concrete approach.
Figure 3-2. Weigh Modules Ready for Removal and Installa tion
Modules have been stacked on the truck for shipping in the order that they are installed (see Figure 3-2). The A
module is the top module, followed by any B modules, and the C module is the bottom module.
6 OTR Truck Scale Assembly Instructions
3.1 Place End Module A
Note
Note
Note
Before lifting the A module from the truck, place four 5 1/2" temporary setting blocks on the concrete fo undation at
each of the four corners. Also re-measure the overall distance between approaches. The OTR series is undersized 1
1/2". When installed in a 70' opening, there will be a 3/4" gap between the approaches and the scale. Minor
adjustments can be made when setting the first module to equally space the scale between approaches.
Depending on foundation and clean out requirements, a different size of setting blocks may be needed.
Assembly instruction references an 18" approach profile for a 5 3/4" clean out. Adjust as needed for your
application needs.
Figure 3-3. Module Positioned on Temporary Setting Blocks
Position each setting block so that it does not interfere with installation of the load cell mounts.
Place module A with the straight end 3/4" from the concrete bulkhead. With 5 1/2" setting blocks, the deck surface
is 1/4"-3/8" from the top of the concrete approach. Square this module with the approach and check that the
side-to-side dimensions are the same.
Figure 3-4. Setting Modules in Place
Before installing the B module, check that no debris has fallen into the two pin-connection receptacles.
Assemble Deck Modules 7
3.2 Place and Attach Adjoining Modules B and C
Note
In a scale with more than two modules, the next module is a B module (see Figure 3-5); if the scale has only two
modules, it is a C module. Place two 5 1/2" setting blocks at the corners opposite of the module support pins (load
cell mount locations) to support the B module.
Figure 3-5. Module B Installation
Place the B module so that the module-support pins engage with the pin-connection receptacles (see Figure 3-6) of
module A and the opposite end rests on the two setting blocks.
Figure 3-6. Pin and Receptacle Interface
If the pins do not seat squarely in the receptacles, raise the module slightly, and then reset the module again.
When the B module is in place, remove the cables or chains from the module and install any other B modules or the
C module in a similar manner.
The C module is installed in the same way that the B module was installed. The end of the C module should be
approximately 3/4" from the approach bulkhead.
The weigh module setup is now complete and the scale is ready to be leveled.
8 OTR Truck Scale Assembly Instructions
Loading...