Rice Lake SURVIVOR PT User Manual
SURVIVOR PT
Pit-Type Truck Scale
Installation Manual
®
53280 Rev C
Contents
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.
1.0 Introduction..................................................................................................................................... 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Foundation Slab Cure Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Assembly Time Estimates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.3 Recommended Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Lifting and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Temporary Setting Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 Assemble Deck Modules ................................................................................................................ 4
2.1 Place End Module A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Place and Attach Center Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Install Outriggers and Deck Coping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Level Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 Load Cell Mount Installation........................................................................................................... 7
3.1 Attach Upper Mount Chair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Prepare Baseplate and Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Raise Mount into Final Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Attach Flexible Conduit Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.1 Attach Grounding Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4.2 Install Lower Module Assembly Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4.3 Install Anchor Bolts and Grout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Install Support Bars, Corrugated Metal, and Deck Rebar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5.1 Corrugated Metal Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Deck Rebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.0 Pour and Finish Concrete Deck .................................................................................................... 12
4.1 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.0 Cable Installation.......................................................................................................................... 14
5.1 Load Cells to J-Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Junction Box to Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Indicator to Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Single-Point Ground Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.5 J-Box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.6 Electrical Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.7 Install Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.0 Trimming and Calibration............................................................................................................. 19
6.1 Overview and Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Trimming Individual Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3 Trimming Paired Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.4 Calibration with Test Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.0 Load Cell Replacement................................................................................................................. 23
7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
© 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.
November 5, 2014
Contents i
Vehicle Scale Limited Warranty............................................................................................................... 24
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars.
For More Information ................................................................................................................................ 25
ii Survivor PT - Pit Type Truck Scale
1.0 Introduction
Note
DANGER
WARNING
CAUTION
Important
WARNING
This manual is intended for use by technicians responsible for installing and servicing the Survivor PT series truck
scale. You will find that the scale has been designed so that your on-site installation time is reduced as much as
possible. A well-organized, experienced installation crew should be able to install a typical 70’x 11’ truck scale in
one day.
This booklet covers the Survivor PT truck scale installations. Use these instructions as general installation
guidelines unless the engineering drawings furnished with the scale differ from the instruction in this booklet.
Engineering drawings furnished with the scale always take priority over these general installation guidelines.
Refer to the engineering drawings furnished with the scale for all component numbering sequences.
Manuals can be viewed or downloaded from the Rice Lake Weighing Systems website at
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
1.2 Installation
Note
The modular sections of the Survivor PT truck scale are shipped pre-assembled and ready to be placed into position
on temporary setting blocks using a crane capable of handling 10,000 lbs. The individual modules are bolted
together and the deck is leveled in final position flush with the top of the pit. Mounts are shipped pre-assembled
with load cells, adapters, and flexible conduit sections attached. Mounts are installed to the level of the deck, then
anchored and grouted to the foundation. Cabling is run in conduit and electronic equipment connected to finish the
installation.
The general assembly order is summarized below:
1. Set deck modules into position on setting blocks and bolt deck modules together.
2. Install outriggers and deck channel coping.
3. Place deck into final position even with top of pit.
4. Assemble mounts with load cells to the deck unit; remove setting blocks.
5. Install mount anchor bolts and grout beneath mount plates.
6. Install corrugated sheet metal, rebar and pour concrete.
7. Run cabling through conduit; make electrical connections.
8. Connect indicator and peripheral devices.
9. Calibrate scale.
1.2.1 Foundation Slab Cure Period
Standard concrete reaches full strength after a 28-day cure. Note that the concrete foundation must cure in a moist
state for at least seven days (three days for high-early concrete). At seven days, standard concrete is approximately
75% of its maximum strength and can handle moderate loads. Loading of a slab before it reaches 75% of maximum
strength may damage the foundation.
1.2.2 Assembly Time Estimates
When scheduling installation for a typical three-section, 70' truck scale, plan for a two-hour minimum crane rental
to position the sections.
A two-man crew, aided by a crane operator, can unload modules from the truck, place them into position and bolt
them together in one to two hours. Mount and load cell installation requires approximately two hours. All electrical
wiring and final connections can normally be completed the same day.
These estimated times may vary.
1.2.3 Recommended Tools and Equipment
The following is a list of recommended tools and equipment necessary to assemble and install the Survivor PT
truck scale:
• One heavy duty crane, equipped with chains or cables, for module placement;
• Rotary hammer drill (3/4");
• Drill with 5/16" socket for installing sheet metal screws through corrugated sheeting;
• Carbide masonry bit (3/4" x 30");
• Two low-profile, four-ton hydraulic jacks;
• Setting blocks (15-1/4") and shims to total 13-3/4" height;
• Torque wrench (800 ft-lb);
• Socket wrenches to 1-5/8" (drive compatible with torque wrench);
• Box end wrenches to 1-1/2";
• Open end wrench set (7/16"-3/4");
• Four-foot bubble or construction level (transit);
• Small torpedo level;
• Spacers for deck-to-pit wall alignment;
• Hammers, maul, pry bar;
• Hand tools for pulling and connecting electrical wiring and sheet metal cutting and trimming.
2 Survivor PT - Pit Type Truck Scale
1.3 Lifting and Handling
Note
7.5"
15.25"
45.5" with grout
44.38" with out grout
23.92"
6.33"
Figure 1-1. Setting Block Diagram.
Note
The top module can be lifted using four chains attached to the four lift lugs
provided with the scale. Once the first module is removed from the truck and is
placed on the setting blocks, the four lift lugs can be removed and used for lifting
and positioning the other modules.
Rice Lake Weighing Systems will credit the customer for the return of the four lift lugs. Please call for an RMA
number.
1.4 Temporary Setting Blocks
Most installers use 15-1/4" temporary setting
blocks for initial module positioning and to aid
in installing deck module bolts. When an end
module is placed into position on the setting
blocks, the top of the module will be 6-1/3"
below the top of the pit. The outriggers and deck
coping are assembled before the load cells
mounts are installed and will bring the top of the
scale to approximately 1/3" below the top of the
pit. Shims are added during final leveling to
raise the deck surface the last 1/3".
Please refer to the construction prints included with the SURVIVOR® Survivor PT truck scale to confirm all
foundation and scale dimensions.
Do not place the setting blocks in the location on the piers where the load cell mounts are to be placed.
Introduction 3
2.0 Assemble Deck Modules
CENTEREND END
Note
Note
Note
Note
The modules are designated either as an end module or a center module. All two-module scales will have two end
modules, while longer scales will have two end modules and one or more center module (Figure 2-1).
Figure 2-1. Center and End Modules
In a three module scale, the end module is the first to be positioned on setting blocks followed by the center
module. The last module to be assembled is an end module. Scales with more than three modules will have
additional center modules installed.
Example – a 100' scale would have two end modules and three center modules.
2.1 Place End Module A
Place one 15 1/4" temporary setting block on the top of each pier and position them so that they will not interfere
with the installation of the load cell mounts. The scale module should be 3/4" away from the bulkhead ramp and
3/4" from each pit wall side. By using the 15 1/4" blocks, the top of the main beam will be approximately 6-1/3"
below the top of the pit.
2.2 Place and Attach Center Module
To assist in easy assembly of the center module, make sure that both modules have direct end-to-end surface
contact.
10. Place four 15 1/4" setting blocks on top of the piers in the center sections.
11. Position and place the center module on the setting blocks, making sure that both the end module and
center module end plates are aligned.
12. Check that the module is centered side-to-side in the pit.
At the installer’s discretion, install the center section with the J-box on the near side to the scale house.
13. When both modules are aligned, insert the top three 1 1/8" bolts with flat washers, lock washers and nuts
on the outside of the beam. (Leave out the bottom bolt to facilitate load cell mount installation).
Tighten bolts and nuts finger tight until all modules are in place.
A long pry bar can be used to make small adjustments in module alignment, but it is easier to leave the
second module attached to the crane for making small alignment changes.
14. Install the three top bolts, washers and nuts on the inside of the beam. Install the bolts, washers and nuts on
the opposite beam using six bolts, washers and nuts. Tighten only finger tight.
Figure 2-2. Top Bolts, Washers, and Nuts Installed
Do not install the bottom bolt at this time.
4 Survivor PT - Pit Type Truck Scale
15. If required, place and install any additional center modules in a similar manner.
Note
Manhole Frame
(24" square)
Note
Top View
To Scale House
Suggested Location of Manhole
Junction Box
Corrugation Support Bar
(remove material as needed
to install manhole frame)
16. Install the remaining end module on four setting blocks ensuring the end beams are aligned with and in
direct surface contact with the center module.
Figure 2-3. Module Installation
17. Center the module side-to-side and check that the end of the main beam is 3/4" from the end of the
concrete pit wall. Install and tighten the three top bolts on each beam (inside and outside) finger tight as in
the previous operation.
Do not install the bottom bolt at this time.
18. To reduce the on-site crane operating time, the manhole frame (shown in Figure 2-4 on page 5) can be
installed at this time. It is recommended to locate the frame in a central location close to the J box as shown
in Figure 2-5 on page 5.
Figure 2-4. Manhole Frame
Before installing the manhole frame, remove a section of the corrugation support bar in the location where the
manhole frame is to be installed. Additional manholes are available as options. Consult with local weights and
measures officials for any state restrictions or access in the state being installed.
OSHA may have restrictions on pit access. Consult with customer’s safety engineers for details.
Figure 2-5. Optimal Manhole Frame Location
Assemble Deck Modules 5
2.3 Install Outriggers and Deck Coping
Outrigger
Note
1/2" Shims Installed
Here if Required
Note
1. Install the outriggers on each module section using 3/4" x 2 1/2" bolts, washe rs and nuts at the locations
shown on the drawing. Torque all bolts to 260 ft-lb.
Figure 2-6. Outrigger Location
2. Position an L-shaped deck coping on top of the outriggers and secure it to the module frame with 1/2" x 2"
bolts, nuts and washers.
3. Assemble the center section deck coping to the end channels using four 2 1/2" bolts, washers and nuts.
4. Attach the third module deck coping to the center section and to the end of the module assembly.
To compensate for irregularities in pit dimensions, 1/2" shims are provided with the truck scale kit assembly.
These shims are to be inserted (if required) between the coping attach points and the module frame assembly.
5. Repeat procedure for the opposite side. Recheck module assembly to see if it is centered side-to-side in the
pit.
Figure 2-7. Optional Shim Placement
As an optional recommended procedure, and to make the module deck coping more rigid, each deck coping may be
tack welded to the outrigger at each contact location. It should be noted that during the concrete pour the deck
coping may bow outward towards the pit walls. To maintain a 3/4" gap between the deck coping and the side of the
pit, it is recommended that temporary spacers (3/4" bolts or shim stock) be used
between the deck coping and the pit wall. Remove spacers after the concrete has set and before the scale is put into
service.
Install the 3/4" bolts or shim stock and space at equal intervals between the deck coping and the pit wall
coping before welding.
2.4 Level Module Assembly
Using a suitable jack and shims, raise each module section so that the top of the deck coping is level with the top of
the pit. After raising module assembly, re-check module alignment to make sure that the top is level and centered
side-to-side in the pit.
6 Survivor PT - Pit Type Truck Scale
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