INSTALLATION GUIDE Version 2.0
INTRODUCTION Carefully read these instructions to assure proper installation and performance of the GatorDeck TM. TOOLS NEEDED 1. Calibrated test weights 2. Phillips screwdriver 3. Flat screwdriver 4. Spanning screwdriver 5. Lifting eye bolts (5/8"-11) 6. Hex screw driver 7. ¾ open end wrench SITE SELECTION & PREPARATION Be careful to select a location that will prevent accidental overloading of the GatorDeck TM. Avoid installing the scale in areas where damage may occur such as impacts from heavy machinery, wheels, forklift tines or shock damage from falling objects. The interface cable between the GatorDeck TM and the indicator must be secured to the floor or wall and protected against crushing, cutting or water damage. If the site has such potential dangers, a method of protection such as running the cable in conduit is recommended. UNPACKING Remove the packing material and inspect the GatorDeck TM for any visible damage caused during shipment. If damage is present, notify your freight carrier immediately to register a claim. Place and secure the GatorDeck TM on forklift tines to remove the four (4) load feet that are stored underneath the scale deck. The GatorDeck TM can also be moved and handled by utilizing 2 eyebolts (5/8"-11) that can be installed at 2 corners of the loading surface. A chain of proper capacity (500lb minimum) can then be used to lift the GatorDeck TM. INSTALLING LOAD FEET Screw a load foot into each load cell and turn all the way in until the top of the foot bolt is level with the top of the load cell. INSTALLATION 1. Place the GatorDeck TM in the selected site. 2. Turn each leveling load foot down until all sides of the GatorDeck TM have ¼ " to ½ clearance from the floor. 3. Assure that each leveling load foot is securely resting on the floor and the GatorDeck TM is level and not rocking. 1
CAUTION: If more than 1/2" clearance to floor is needed, the bottom of the leveling load foot must be shimmed. Assure the leveling load foot bolt thread engagement is a minimum of 50% into each of the load cells. 4. Tighten leveling load foot lock nut against load cell. Be careful not to overtighten. NOTE: May cause reading errors, which will require re-calibration. 5. Secure the OSHA yellow load cell cable to the floor or wall. Take care not to stretch or bind cable as this will effect weight readings. 6. Connect the OSHA yellow load cell cable to the weight indicator. Reference the indicator User and Installation Guide for proper connections. LOAD CELL WIRING TO JUNCTION BOX The four (4) load cells are each wired to their respective terminals in the junction box according to the corner numbering system shown in Figure 1 below. See Figure 2 on page 3 for junction box layout and wiring connections. Tighten the strain relief hubs on the junction box with a wrench to assure proper seal. Figure 1: Load Cell Configuration 2
Figure 2: Junction Box Connections Take the cable coming from the junction box of the GatorDeck TM and wire it to the indicator connector as follows: Table 1: Connector Wiring WIRING DESIGNATION WIRE COLOR (+) Excitation Red (-) Excitation Black (+) Signal Green (-) Signal White (+) Sense Blue (-) Sense Brown Ground or Shield Clear CALIBRATION INSTRUCTIONS 1. Calibrate the GatorDeck TM to indicator per instructions supplied with your indicator. 2. After calibration has been completed, take a known weight (ideally 25% of capacity) and check each corner. Place weight between center of scale and each corner one at a time as shown in Figure 2: Junction Box Connections. Use the same calibrated weight in each corner. 3. If the indicator weight reading deviates from the known weight the junction box trim pot for that corner should be adjusted. A qualified Scale Technician should perform this procedure. Call your GSE Distributor for service. 4. To adjust the corner weight readings, use the trim pot designated for that corner which is numbered the same as the corner you need to adjust. Turning the pot clockwise increases the weight reading. Refer to Figure 1: Load Cell Configuration for the correct location. 5. After each corner has been checked and calibrated, make a final check of your calibration in all corners and center of GatorDeck TM, 6. The GatorDeck TM is now calibrated and ready for use. 3
LOAD CELL REPLACEMENT Should a load cell become damaged due to an overload condition, replacement load cells can be ordered from GSE Scale Systems according to the part numbers in the chart on page 6. 1. Unbolt the defective load cell, and then remove leveling load foot from the load cell. 2. Disconnect load cell cable from junction box and attach a chase wire to the load cell cable. DO NOT CUT THE LOAD CELL CABLE! 3. Pull the load cell cable out of the formed frame channels. The chase wire will be used to pull the new load cell cable through the formed channel. 4. Install the new load cell by reversing the preceding steps. Reference the wiring diagram in Figure 3. 5. To verify correct load cell/junction box terminal matching, see the numbers on the terminals inside the junction box and the corner numbering diagram in Figure 1: Load Cell Configuration. 6. Position load cells with load cell alignment arrow pointing up toward the deck. With the torque wrench, tighten all mounting bolts to 75 ft./lbs. 7. Route the load cell cables in each corner so that the cable is free from possible contact with the load cell or load foot. Pull cable tight towards junction box, coil up extra length with cable ties and securely store inside channel. 8. Pass end of load cell cable through cable fittings in the NEMA 4X junction box. Corner correction trimming and calibration is necessary after load cell replacement. Follow the calibration instructions on page 3. Figure 3: Gator Deck Bottom View 4
OPTIONS FLOOR ANCHOR PLATE INSTALLATION (optional) Two anchor plates are available, as an option, to prevent the GatorDeck TM from moving. To install the Anchor Plates, lift the scale until the leveling load feet are approximately 1" clearance from the floor. Slide anchor plates under two diagonally opposed load feet. Lower the scale back to the floor and position the plates so that the anchor plate mounting holes are accessible. Using the anchor plate as a template, drill pilot holes into the floor for anchor bolts. Bolt the anchor plates to the floor using 1/2" anchor bolts. Verify level and alignment with anchor plates. BUMP RAMP INSTALLATION (optional) Bump Ramps protect the GatorDeck TM from damage that can occur from a side load impact caused by machinery and forklifts. NOTE: Installation of bump ramps is done as the last step of a scale base installation. 1. Place bump ramp in position over the GatorDeck TM, assuring a minimum of ¼ " clearance from the scale to avoid any mechanical contact that could cause errors. 2. secure bump ramp to the floor, using the mounting holes provided and 3/8" anchor bolts. DRIVE-ON RAMP INSTALLATION (optional) Drive-on ramps provide a safe access for hand trucks and forklifts. Drive-on ramps are bolted to the floor with built-in plates that capture the leveling load foot. 1. Using the built-in plates as a template, drill pilot holes into the floor for anchor bolts. 2. Mount the ramp securely to the floor using ½ " anchor bolts. 3. Place scale next to ramp with leveling load feet locked inside plates. 4. Adjust scale height to be level with ramp. Figure 4: Drive on Ramp 5
REPLACEMENT PARTS Figure 5: Exploded Parts View Table 2: Replacement Part Numbers REF PART NO DESCRIPTION 3 E0-50302 Load cell shear beam 1,000 lb capacity 3 E0-50303 Load cell shear beam 2,500 lb capacity 3 E0-50304 Load cell shear beam 5,000 lb capacity 4 M0-00039 Load foot 3" dia rigid rubber 1/2-20 bolt 2.5" long 5 M1-12308 Screw ½-20 x 1.75 HEX HD grade 5 zinc plate 6 M1-11724 Screw ¼-20x3/4 Allen FL HD stainless steel 7 M1-61527 Seal 1/8" cable with nut HEYCO 8 E0-81280 Assembly sum/trim PCB only 8 E0-81287 Assembly sum/trim J-Box complete 6
GATOR DECK TM USER GUIDE E0-90200 Version 2.0 10/1/02