Rice Lake Survivor PL User manual

Survivor® PL
Low Profile Modular Railroad Track Scale
Installation Manual
PN 98740 Rev EOctober 18, 2022

© Rice Lake Weighing Systems. All rights reserved.
Rice Lake Weighing Systems® is a registered trademark of
Rice Lake Weighing Systems.
All other brand or product names within this publication are trademarks or
registered trademarks of their respective companies.
All information contained within this publication is, to the best of our knowledge, complete and
accurate at the time of publication. Rice Lake Weighing Systems reserves the right to make
changes to the technology, features, specifications and design of the equipment without notice.
The most current version of this publication, software, firmware and all other product
updates can be found on our website:
www.ricelake.com

Revision History
© Rice Lake Weighing Systems ● All Rights Reserved 3
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.
Revision History
This section tracks and describes manual revisions for awareness of major updates.
Revision Date Description
EOctober 18, 2022 Revision history established; updated graphics representing scale platform
Table i. Revision Letter History

Contents
Survivor PL - Low Profile Modular Railroad Track Scale
4 Visit our website www.RiceLake.com
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Foundation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Scale Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Approach and Dead Space Hardware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Rail Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.0 Junction Box and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Load Cells to Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Junction Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Junction Box to Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Indicator to Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Single-Point Ground Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Electrical Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.0 Trimming and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Trim Load Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2.1 Static Testing of a Track Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.2 Strain Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Introduction
© Rice Lake Weighing Systems ● All Rights Reserved 5
1.0 Introduction
This manual is intended for use by service technicians responsible for installing and servicing low profile modular railroad track
scales.
Manuals and additional resources are available from Rice Lake Weighing Systems at www.ricelake.com/manuals
Warranty information can be found at www.ricelake.com/warranties
NOTE: Use these instructions as general installation guidelines unless the engineering drawings furnished with the scale
differ from the instructions in this manual. Engineering drawings furnished with the scale always take priority over the
general installation guidelines.
1.1 Safety
Safety Definitions:
DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Includes
hazards that are exposed when guards are removed.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in serious injury or death. Includes
hazards that are exposed when guards are removed.
CAUTION: Indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury.
IMPORTANT: 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 this manual has been read and all instructions are understood.
Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Rice Lake
Weighing Systems dealer for replacement manuals.
WARNING
Failure to heed could result in serious injury or death.
Some procedures described in this manual are potentially dangerous. These procedures are to be performed by qualified service
personnel only
Do not allow children or inexperienced persons to operate this unit.
Do not operate without all shields and guards in place.
Do not use for purposes other then weight taking.
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.

Survivor PL - Low Profile Modular Railroad Track Scale
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2.0 Installation
DANGER: Crush hazard, keep hands, feet and other body parts clear when setting weigh modules in place. Moving parts
can crush and cut.
Recommended Tools and Equipment
Below is a list of recommended tools and equipment necessary to assemble and install the Survivor PL Rail Scale.
2.1 Foundation Installation
For installation, reference the foundation drawings supplied with the scale.
• Do not start construction of the foundation without having certified prints.
• Pour the scale slab(s).
• Pour the approach slab and, if applicable, intermediate section over rebar or optional anchor bolts.
• Use Handbook 44 and AAR Handbook Guidelines for Legal for Trade
NOTE: Anchor bolts should protrude from the concrete enough for the lower base plates to be secured onto them.=
IMPORTANT: Failure to heed the following could result in damage to the concrete and equipment.
* 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.
* Standard concrete does not reach full strength until after a 28-day cure.
• Two 10 ton bottle jacks, 12 in or shorter
• 24 wooden blocks 6 in x 6 in x 24 in oak
• 24 wooden blocks 4 in x 4 in x 24 in oak
• 24 wooden blocks 2 in x 4 in x 24 in oak
• Flat blade screw driver
• Small blade screw driver for adjusting j-box pot.
• #2 Phillips screw driver
• Transit
• Small magnetic level
• Large funnel with 1 in opening in bottom
• 24 in plastic pipe to attach to above funnel for
pouring grout
• 1 5/8 in combination wrench
• 1 5/8 in socket
• 15/16 in socket
• 1 1/4 in socket
• 1 1/4 in combination wrench
• 1 1/8 in socket
• 2 in combination wrench
• 2 in socket
• 3/8 in Allen wrench
• 7/16 in socket
• Multi meter
• Pliers
• Torque wrench capable of torquing up to 250 ft lb for 1
1/4 in socket & 2 in socket
• Fish tape for pulling wires
• Line up punch for aligning holes
• Large hammer
• Latex caulk for sealing grout forms
• Caulk gun for above caulk
• 1 in x 4 in wood for building grout forms

Installation
© Rice Lake Weighing Systems ● All Rights Reserved 7
2.2 Scale Installation
Use the following steps to install the scale.
Figure 2-1. Leveling Bolts Installed into Lower Base Plate
1. Set load cell lower base plates over the pre-cast anchor bolts.
2. Install leveling bolts into base plates.
Figure 2-2. Load Cell, Spacer Block, and Base Plate
3. Install load cell, spacer plate and base plate onto lower base plates.
Leveling bolts
Load cell lower
base plate
Anchor bolts
Load cell
Load cell base plate
Load Cell Installed
Load cell
spacer plate

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Figure 2-3. Install Brackets
4. Set longitudinal check brackets and lateral side check brackets over pre-cast anchor bolts.
Figure 2-4. Check Rod Locations
NOTE: The rods for the checking system, should be placed beneath the scale prior to setting of the modules. Bracket
quantity varies depending on number of scale sections.
Check rod bracket
End rail support plate
DD
C
C
C
C
Section C-C Section D-D
Check Rod
Check Rod
Check Rod Bracket Check Rod Bracket

Installation
© Rice Lake Weighing Systems ● All Rights Reserved 9
Figure 2-5. Upper Load Cell Plate Mounting Procedure
5. Remove steel top plates from weigh module. Mark the plates to identify their location for re-assembly.
6. Install bearing block, upper mount plate, spacer tubes, bearing cushions and shim plate in each load cell pocket of the
weigh module.
WARNING: Crush hazard, keep hands, feet and other body parts clear when setting weigh modules in place. Moving parts
can crush and cut.
Figure 2-6. Weigh Module on Setting Blocks
7. Set the weigh module on 5 in setting blocks. Center the module between approaches.
Install upper load
cell components
Weigh Module Pocket
Ground Strap
Connection
When bolts are tight,
plates will be movable
Wooden setting block

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Figure 2-7. Module Elevation
8. Using a jack and shims, level the module and set its elevation between 2 1/8 in and 2 1/4 in above concrete
approaches.
Figure 2-8. Load Cell Assembly
9. Using leveling bolts, raise and level the load cell assemblies to contact the upper mount bearing plates.
Figure 2-9. Check Rod Level with Horizontal Plane
10. Jack the weigh module to allow removal of setting blocks and shims.
11. Install the lower base plate, washers and nuts.Do not torque nuts until after plates are grouted and cured.
12. Install check rods and hardware. Ensure check rods level with a horizontal plane to within +/- 2 degree.
13. Weld spacer plates (PN 71860) to the weigh module to secure it in place.
14. Repeat steps 1-13 for the second weigh module.
Jack
Load Cell
Leveling Bolts
Upper Load Cell
Mount Plate
Check Rod