Rice Lake SURVIVOR PT User manual

53280
SURVIVOR PT
Pit-Type Truck Scale
Assembly Instructions
®

Survivor® PT Pit-Type Truck Scale Assembly Instructions

Technical training seminarsare available through Rice Lake Weighing Systems.
Course descriptionsand datescan be viewed at www.ricelake.com or obtained
by calling 715-234-9171 and asking for the training department
© 2007 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
February 2007
Contents
Introduction.............................................................................................................................................. 1
1.0 Installation ................................................................................................................................... 1
1.1 Foundation Slab Cure Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Assembly Time Estimates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Recommended Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Lifting and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Temporary Setting Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Assemble Deck Modules ............................................................................................................. 3
2.1 Place End Module A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Place and Attach Center Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Install Outriggers and Deck Coping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Level Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Load Cell Mount Installation........................................................................................................ 6
3.1 Attach Upper Mount Chair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Prepare Baseplate and Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Raise Mount into Final Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Attach Flexible Conduit Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.1 Attach Grounding Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.2 Install Lower Module Assembly Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Install Anchor Bolts and Grout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Install Support Bars, Corrugated Metal, and Deck Rebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6.1 Corrugated Metal Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Deck Rebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.0 Pour and Finish Concrete Deck ................................................................................................... 9
4.1 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.0 Install Cabling in Conduit .......................................................................................................... 11
5.1 Load Cells to Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Junction Box to Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3 Indicator to Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.4 Single-Point Ground Conductor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.5 Junction Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.6 Electrical Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.7 Install Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.0 Trimming and Calibration.......................................................................................................... 15
6.1 Overview and Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Trimming Individual Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Trimming Paired Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Calibration with Test Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.0 Load Cell Replacement.............................................................................................................. 18
7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.0 Vehicle Scale Limited Warranty ................................................................................................ 19

ii Survivor® PT Pit-Type Truck Scale Assembly Instructions

Installation 1
Introduction
This manual is intended for use by technicians
responsible for installing and servicing the PT
Pit-Type series truck scale. You will find that the PT
Pit-Type truck 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.
NOTE: This booklet covers the PT Pit-Type truck scale
installations. Use these instructions as general installation
guidelines unless the engineering drawings furnished with
your scale differ from the instruction 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
www.ricelake.com.
1.0 Installation
The modular sections of the SURVIVOR®PT Pit-Type 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.
1.1 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 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.
Note: These estimated times may vary.

2Survivor® PT Pit-Type Truck Scale Assembly Instructions
1.3 Recommended Tools and Equipment
The following is a list of recommended tools and equipment necessary to assemble and install the SURVIVOR®
PT Pit-Type 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 (12-1/4") 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.
1.4 Lifting and Handling
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.
NOTE: Rice Lake Weighing Systems will credit the customer for the return of the four lift lugs.
Please call for an RMA number.
1.5 Temporary Setting Blocks
Most installers use 12-1/4" 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".
NOTES:
• Please refer to the construction prints included with the SURVIVOR® PT
Pit-Type 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.
7.5"12.25"
42.5"
23.92"
6.33"
Figure 1-1. Setting Block Diagram.

Assemble Deck Modules 3
2.0 Assemble Deck Modules
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 (see
diagram below).
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 threee modules will
have additional center modules installed. As an
example, a 100' scale would have two end modules
and three center modules.
2.1 Place End Module A
Place one 12-1/4" 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 (see
figure on right). By using the 12-1/4" 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
NOTE: To assist in easy assembly of the center module, make
sure that both modules have direct end-to-end surface
contact.
1. Place four 12-1/4" setting blocks on top of the
piers in the center sections.
2. Position and place the center module on the
setting blocks, making sure that both the end
module and center module end plates are
aligned.
3. Check that the module is centered side-to-side
in the pit.
NOTE: At the installer’s discretion, install the center section
with the J-box on the near side to the scale house.
4. 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).
NOTES:
• 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.
5. 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.
NOTE: Do not install the bottom bolt at this time.
Figure 2-2. Top bolts, washers, and nuts installed.
6. If required, place and install any additional
center modules in a similar manner.
7. 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.
8. 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.
NOTE: Do not install the bottom bolt at this time.
CENTEREND END

4Survivor® PT Pit-Type Truck Scale Assembly Instructions
9. To reduce the on-site crane operating time, the
manhole frame (shown in photograph on
right) 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 the
diagram below.
Figure 2-4. Manhole frame.
NOTES: 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.
2.3 Install Outriggers and Deck
Coping
1. Install the outriggers on each module section
(as shown on below) using the 3/4" x 2-1/2"
bolts, washers 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 using the 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.
NOTE: 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
Manhole Frame
(24" square)
Top View
To Scale House
Suggested Location of Manhole
Junction Box
Corrugation Support Bar
(remove material as needed
to install manhole frame)
Outrigger
1/2" Shims Installed
Here if Required

Assemble Deck Modules 5
between the deck coping and the pit wall. Remove spacers after the concrete has set and before the scale is put
into service.
NOTE: Install the 3/4" bolts or shim stock and space at equal intervals between the deck coping and the pit wall coping before
welding as shown in the drawing on the right.
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.

6Survivor® PT Pit-Type Truck Scale Assembly Instructions
3.0 Load Cell Mount Installation
Load cell mounts, complete with load cells and
conduit adapters, have been assembled at the factory
to save on-site installation time. Load cell mount
installation consists of sliding the complete unit into
place beneath the deck, raising the mount with the
leveling screws to the deck, and connecting the
grounding strap.
When installing load cell mounts, start at one corner
of the module assembly and install the remaining load
cell mounts on that side. Likewise, when the load cell
mounts are installed on the other side, start with the
corner of the module assembly.
The lower mounts assemblies come complete with
load cells installed, so complete any necessary
welding on the scale before installing mounts.
NOTE: Remove load cell mount from packing box and file
printed load cell Certification of Conformance (CC) in a safe
place for future reference.
3.1 Attach Upper Mount Chair
1. Attach the upper chair to the bottom of the
module assembly by using four 3/4" bolts
with washers making sure that the 1/4" hole
for ground strap installation is toward the
center of the scale module.
Figure 3-1. Upper chair bolts installed.
2. Torque upper chair bolts to 260 ft-lb.
3.2 Prepare Baseplate and Mount
Installation
1. Turn the four levelling screws through the
baseplate so approximately 1/2" extends
beyond the bottom surface.
2. Each load cell mount comes equipped with a
90-degree threaded LB conduit adapter.
Orient the adapter so that the cable will point
toward the inside of the scale when mounted.
NOTE: Each mount must be oriented so the cable exit from
the load cell is facing the interior of the module to which it will
be attached. The correct orientation will place the flexible
conduit section on the load cell near the rigid conduit attached
to the weighbridge.
3. If a load cell must be reversed to achieve
correct orientation, remove a load cell and
reverse its direction in the field. When
retightening load cell bolts, torque to 70 to 80
ft-lb. The 90 degree fitting on the flexible
conduit attached to a load cell can rotate 180
degrees to allow for correct conduit
placement.
4. Set the mount assembly on the concrete pier
directly in front of its final position. Carefully
slide the mount into position under the upper
chair.
3.3 Raise Mount into Final Position
1. Turn the leveling screws to raise the mount
until the link is centered in the chair bearing
and lightly touching.
2. Level the plate in both directions.
3. When the baseplate is directly under the chair,
the link will be hanging vertical when
centered in the chair (see figure on left).
Approximately 1/4" of the link should
protrude (see figure below) beyond each side
of the chair.
Figure 3-2. Final mount position.
4. If adjustment is necessary, tap baseplate edges
lightly with a hammer to slide the entire
mount sideways.
Figure 3-3. Load Cell Mount Parts.
UPPER CHAIR
LINK
1/4" PROTRUSION
LOAD CELL
LEVELING SCREW
BASEPLATE
1/2"