Field Service Manual

Transcription

1 Field Service Manual

2 Table of Contents SOP-011 SOP-023 WI-0013 WI-0019 WI-0021 WI-0026 WI-0027 WI-0028 WI-0030 WI-0036 WI-0038 WI-0041 WI-0042 WI-044 WI-045 WI-046 WI-0048 WI-0049 WI-0050 WI-0051 WI-0052 WI-0054 Number Title Inspection and Testing Field Inspection and Testing Scale Stickers Scale Installation Testing Monorail Scales Visual Inspection of Scales w/digital Indicators Printer Inspection Visual Inspection of Load Cells Stock Scale and Preventive Maintenance Testing Truck Scale for Poultry and Livestock Testing Above-Ground Truck Scales for Poultry and Livestock Portable/Floor Scale Maintenance Bench and Counter Scale Preventive Maintenance Shift Test Load Test Truck and Track Scale Maintenance Visual Inspection of Scale Pits and Lever System for Truck & Track Scales Visual Inspection of Above Ground Truck & Track Scales Shift Test for Truck & Track Scales Load Test for Truck & Track Scales Tank and Hopper Scale Maintenance Load Receiver Visual Inspection of Tank/Hopper Scales

3 WI-0055 WI-0057 WI-0059 WI-0060 Testing Tank and Hopper Scales Fine Increment and Counting Scale Maintenance Shift Test for Fine Increment/Counting Scales Load Test for Fine Increment/Counting Scales

4 SOP-011 Inspection and Testing (pg 1 of 2) 1. ISO 9002, 1994, Section Field Service Quality Policy, Section This procedure assigns responsibility and provides a system and instructions for performing and recording final inspections. 2. Responsibility and Application: 2.1 Final inspection is done upon delivery or installation at the customer s facility by the assigned technician. 3. Conducting the Inspection: 3.1 The purpose of the final inspection is to assure that the equipment meets all standards and tolerances as determined by NIST Handbook, H-44, or manufacturer s specification. The final inspection consists of the following: Review the needs required by the customer Visual inspection to detect any visual quality problems Ensuring equipment is performing accurately by application of certified test weights When equipment has passed all tests, a calibration sticker will be placed on the equipment. The sticker will be dated and initialed by the technician. 3.2 See the Calibration Sticker for a sample. 4. Records: 4.1 Field Service personnel perform the final inspection. The equipment is inspected and tested according to the Standard Operating Procedures and Work instructions related to the task as listed in the Documentation Structure List. 4.2 The final inspection record is established upon delivery, completion, installation, testing, and final calibration of the equipment. The Service Technician completes the final test report and the Customer Service Report per the Work Instructions. If all weighing equipment installed meets the calibration requirements of NIST Handbook, H-44, the Field Service Technician marks the Customer Service Report Job Complete. This indicates the weighing equipment has passed according to defined acceptance criteria. The Service Technician and the customer sign and date the Customer Service Report to verify that all work was performed and accepted. 5. Non-Conforming Product: 5.1 If any equipment proves to be non-conforming, the technician tags the equipment and initiates a Non-Conformance Report. The equipment is returned to the Service Center, where it is segregated in the non-conforming product, to await final disposition, as specified in SOP-013,

5 SOP-011 Inspection and Testing (pg 2 of 2) Inspection and Test Status Procedure and SOP-019, Quality Records. 6. Non-Conforming Product Records: 6.1 The storage location and retention period for non-conforming products are specified in SOP-019, Quality Records.

6 SOP-023 Preventive Maintenance Service ISO 9002, 1994, Section Field Service Quality Policy, Section Scope: 2.1 This procedure assigns responsibility, methods for Preventive Maintenance Service. These methods are used to evaluate and maintain the Quality Standard as prescribed in the Quality Manual and Standard Operating Procedures. 3. Application: 3.1 Check in with customer front desk and/or person authorized to approve of service. 3.2 Ask if there are any problems and/or errors with scales. 3.3 Do a walk-through to locate all the scales to be serviced. If some scales cannot be found, have customer locate while you begin service on found scales. 3.4 If the customer's authorized representative indicates a scale has a problem then the technician will evaluate the scale based on the authorized representative's priority (must be evaluated now or can wait until after preventive maintenance is complete). The technician will take up to 10 (ten) minutes to evaluate the scale. 3.5 If a problem-scale must be repaired and the customer-authorized representative indicates a high priority so that the preventive maintenance service must be interrupted then the technician can interrupt the preventive maintenance service and fix the problem-scale. If any of the day's scheduled preventive maintenance service must be rescheduled the technician must call the Service Manager to reschedule the service. This may require rescheduling the preventive maintenance service and doing the repairs immediately. 3.6 If the problem-scale must be repaired and the customer-authorized representative indicates a low priority, the technician must call the Service Manager to schedule the repair. The Service Manager may schedule repair to be done right after completion of preventive maintenance or at a later date. 3.7 If a problem is found with a scale, the technician will take up to 10 (ten) minutes to make an evaluation and fix scale. If it will take longer than 10 (ten) minutes, technician will make a note on his worksheet and move on to next scale. See Step 3.3 to determine when to fix problem-scale. 4. Reporting 4.1 A separate Customer Service Report (CSR) for the preventive maintenance service and for any repairs that take more than 10 (ten) minutes must be completed by the technician and signed by the customer-authorized representative. If the technician must leave and come back later either to finish the preventive maintenance service or repairs,another CSR must be completed with time and truck charges included and signed by the customerauthorized representative. 4.2 The CSR for the preventive maintenance service must note any repair recommendations and status of repair. 4.3 The CSR for the repair(s), if done, must indicate any and all parts used and the status of the repair(s). 4.4 The technician will review the CSR and all other paperwork with the customer making special notice of the status of any broken and unrepairable scales. 4.5 Customer must sign the CSR(s). 4.6 The hours on the CSR must match the technician's corresponding Time Sheet. 4.7 If required, immediately fax Test Reports to Weights and Measures.

7 WI-0013 Scale Stickers 1. SOP-010, Inspection and Testing 2. SOP-011, Inspection, Measuring, and Testing Equipment 1.1 This procedure establishes how technicians will use a scale inspection sticker and how it will be completed and applied on the device so as to be clearly visible The stickers use by Left Coast Scales Service will have the Left Coast Scale logo as well as the address and phone number imprinted on it. It will be the manager s responsibility to see that his technicians complete the sticker and place it on the device where it is clearly visible. The sticker will have blank spaces for the following information: Dated tested Signature of servicing technician Next calibration due date 2.2. The servicing technician will be responsible for completing this information, signing the sticker and placing it on the device The sticker will be similar to this in layout: PLACE STICKER HERE 2.4. If stickers are made up locally to meet a specific customer requirement, it must still contain the above information Multiple-purpose stickers such as stickers with all months listed on them should not be used unless the device is actually being tested monthly.

8 WI-0019 Installation 1. SOP-009, Process Control. 1.1 This procedure establishes how Left Coast Scale technicians handle installations of new equipment and what procedure they will follow to complete the installation and place the scale in service Left Coast Scales sells and installs this type of weighing equipment This new equipment, when sold, is installed by skilled Left Coast Scale technicians These scales are shipped disassembled and require assembly at the job site Each installation is completed using certified drawings furnished by the manufacturer Mechanical and/or electronic components are assembled on properly designed foundations, plumb, level and square per the certified drawings Truck and track scales are tested per Maintenance Work Instruction WI-0046 and placed in service Stock scales are tested per Maintenance Work Instruction WI-0030 and placed in service Floor scales are tested per Maintenance Work Instruction WI-0041 and placed in service Tank and hopper scales are tested per Maintenance Work Instruction WI-0052 and placed in service Installation of small scales (ones that don t require field assembly) are simply unpacked, set up and leveled then tested and calibrated and placed in service per Work Instruction WI-0042 for Bench and Counter scales.

9 WI-0021 Testing Monorail Scales (Pg. 1 of 2) 1.1 This Work Instruction establishes how Left Coast Scales technicians will perform tests and what data will be recorded for monorail scales as part of a standard preventive maintenance service inspection Review customer files for any special instructions or specific requirements. Include these as steps in this procedure Use the Monorail Scale Test Report Form as a record of this inspection and test. Follow Work Instruction WI-0029 for completion of test report. Record pertinent information and/or comments in repairs or recommendations section Consult with the operator to determine if they have noticed any problems. Record all such feedback in repairs section including how the issue was resolved Complete historical information at the top of the Monorail Scale Test Report Form per Work Instruction WI Inspect load receiver to see that it s level and secured in place and that there is adequate clearance on both ends of live rail (1/8 minimum). The transition from dead rail to live rail should be smooth Perform visual inspection of digital indicating device per Work Instruction WI For monorail scales with printers, perform Maintenance of Printers Work Instruction WI Inspect load cells and wiring per Work Instruction WI Counter poise weights, if used, must be examined and identified by serial/part number along with comments regarding their condition in the designated section Pertinent information regarding the test and general condition of scale must be posted in the recommendations section Confirm that all required identification markings for load receiver, indicator and printer are in place and legible per H Seal scale and components that must be secured from unauthorized adjustments.

10 WI-0021 Testing Monorail Scales (Pg. 2 of 2) Instruct operating and maintenance personnel of proper operation and maintenance when scale condition or customer indicates the need Complete the Monorail Scale Test Report Form. Review results with customer, get signoff and distribute Apply scale sticker where it is clearly visible indicating date of test, signature of technician conducting test and date of next calibration per Work Instruction WI Notify state or county Weights and Measures and/or P&S as is appropriate.

11 WI-0026 Visual Inspection of Scales with Digital Indicators 1.1 This Work Instruction establishes how Left Coast Scales technicians will visually inspect scales with digital indicators and the records to be kept as part of a standard preventive maintenance service inspection Visually inspect housing for damage Visually inspect all external cables and connectors for damage and to be sure all connections are secure When housing is opened, check terminal strips and boards to be sure all connections are secure. Check gaskets/seals to be sure they aren t damaged. Report any potential problems in remarks section and review with customer and repair as necessary.

12 WI-0027 Printer Inspection 1.1 This Work Instruction establishes what Left Coast Scales technicians will do during a visual inspection of scales with printers while performing a Preventive Maintenance Service inspection Visually inspect and clean printer and/or type bars Check for print clarity Spot check to see that printer is printing the same weight as that indicated. Record any problems in the actions taken/remarks section Check for conformance to Weights and Measures codes for printers per H44.

13 WI-0028 Visual Inspection of Load Cells 1.1 This Work Instruction establishes what Left Coast Scales technicians will do during a visual inspection of scales with load cells and what data will be recorded as part of a standard preventive maintenance service inspection Visually check cells for any obvious damage or obstructions Check single cell applications to see that they are plumb and all hardware is secure Visually inspect hardware on cells and their mounting assemblies to assure that everything is secure and properly aligned as per standard installation procedures Visually inspect all wiring and cables to assure that it s not damaged or defective Visually inspect summing boxes and SVP boxes, if applicable, for moisture or other foreign matter that could cause problems If problems are found in any of the above areas, take corrective actions as is appropriate and record those actions on the Customer Service Report and test reports for customer review.

14 WI-0030 Stock Scale Preventive Maintenance (Pg 1 of 2) 1.1 This Work Instruction establishes what Left Coast Scales technicians will perform for tests and what data will be recorded for Stock Scales as part of a standard preventive maintenance service inspection Review customer file for any special requirements. Include them as steps in this Work Instruction Consult with scale operator to determine if he has had any problems with the operation of the scale. Record pertinent information as a remark on the Standard Test Report Form, including how resolved Complete historical information on the Standard Test Report Form per Work Instruction WI Perform visual inspection of pit per Work Instruction WI-031. Comments and/or pertinent observation are to be posted in the repair or recommendations section of the Standard Test Report Form For scales with a mechanical indicator, perform Work Instruction, Maintenance of Mechanical Indicators WI For scales with digital indicator, perform Work Instruction, Maintenance of Digital Indicators WO For scales with printer, perform Work Instruction, Maintenance of Printers WI For scales with load cells, perform Work Instruction, Maintenance of Load Cells WI After visual inspection of all components is complete, scale is balanced to zero and ready for testing. Use the Standard Test Report Form Perform SR test per Work Instruction WI Conduct shift or corner test per H44 and Packers & Stockyards Administration recommendations using test load equal to 25% of scale capacity per Work Instruction WI Conduct build-up or distributed load test per H44 and in conformance with Packers & Stockyards Administration recommendations per Work Instruction WI-0034.

15 WI-0030 Stock Scale Preventive Maintenance (Pg 2 of 2) For scales with mechanical dials or digital indicators, P & S requires that a decreasing load test be conducted per Work Instruction WI If scale is within maintenance tolerance (2/10 th of 1% of applied load or 1 graduation, whichever is greater), no further adjustments are necessary If scale is out of maintenance tolerance and adjustments are made, the above test must be repeated and the tolerance reduced to 1/10 th of 1% or 1 graduation, whichever is greater After conducting tests and adjusting scales within tolerance, seal those components which must be secured from unauthorized adjustments Instruct scale operating and maintenance personnel of proper operation and maintenance procedures when scale condition or customer indicates the need Finish the Standard Test Report form. Review with customer and get sign-off and distribute Apply scale sticker where it is clearly visible indicating date tested, signature of technician conducting test and date of next calibration Notify state or county Weights and Measures and/or Packers and Stockyards as is appropriate.

16 WI-0036 Testing Truck Scales Used To Weigh Poultry and Livestock (pg. 1 of 2) 1.1 This Work Instruction establishes what Left Coast Scales technicians will perform for tests on a vehicle scale used to weigh poultry or livestock, and what data will be recorded as part of a standard preventive maintenance service inspection. P & S requires that we use Form P&SA-216 when testing a vehicle scale used to weigh poultry or livestock and that a copy of the report be mailed to them each time a test and calibration is completed Review customers file for any special requirements. Include them as steps in this Work Instruction Use Test Report Form P&SA-216 (latest Issue) and complete per Work Instruction WI Consult with scale operator to determine if he has had any problems with the operation of the scale. Record pertinent information under recommendations section on Test Report Form P&SA- 216 including how resolved Check the condition of the deck. Record observations in the actions taken/remarks section With pit type scales, perform visual inspection per Work Instruction WI Comments and/or pertinent observations are to be posted under recommendations portion of Form P&SA With above ground scales perform visual inspection per Work Instruction WI Comments and/or pertinent observations are to be posted in the Conditions of portion of Form P&SA For a mechanical indicator, perform Work Instruction WI For a digital indicator, perform Work Instruction WI For scales with printer, perform Work Instruction WI For scales with load cells, perform Work Instruction WI After visual inspection of all components is complete, scale is ready for testing. Use Test Report form P&SA Perform Increasing Load Test Work Instruction WI-0040.

17 WI-0036 Testing Truck Scales Used To Weigh Poultry and Livestock (pg 2 of 2) Perform strain load test on each section per Work Instruction WI If scale is found out of tolerance, make adjustments to correct and retest. Notify customer to determine if next calibration date is to be adjusted to other than the schedule. The calibration date could be moved up to prove the scale will hold calibration If scale is in tolerance, no other testing is necessary Seal scale and those components which must be secured after authorized adjustments Instruct scale operating and maintenance personnel of proper operation and maintenance Work Instruction when scale condition or customer indicates the need Finish Test Report Form P&SA-216. Review with customer and get sign off and distribute Apply scale sticker where it is clearly visible indicating date tested, signature of technician conducting test and date of next calibration Notify state or county Weights and Measures and/or P & S as is appropriate.

18 WI-0038 Inspecting Above-Ground Truck Scales 1.1 This Work Instruction establishes what Left Coast Scale technicians will do during a visual inspection of above ground truck scales used to weigh poultry and livestock as part of a standard preventive maintenance service inspection Visually check deck and approaches for damage Visually check ends, sides and surface area under deck for foreign matter. Remove obstructions. Report major problems (i.e. cleaning jobs) to customer in comments section for followup corrective actions Visually check load cells and cabling per Work Instruction WI Check deck for proper oscillations. Deck should oscillate 3 to 5 times before stopping. Adjust bumper bolts if necessary to reduce oscillations Rigid checking systems should be visually checked to make certain they are properly aligned and secure and are not causing unwanted friction.

19 WI-0041 Portable Floor Scale Maintenance (pg. 1 of 2) 1.1 This Work Instruction establishes what Left Coast Scales technicians will perform for tests and what data will be recorded for floor scales less than 30,000 lbs. as part of a standard preventive maintenance service inspection Review the customer s file for special work instructions outlining specific requirements to be performed Use the Customer Service Report and the Standard Test Report as a record of this inspection following Work Instruction for Completion of Test Report WI Record observations and repairs in Action taken/remarks section Consult with the scale operator to determine if he has any problems with operation of the scale. Record pertinent information as a remark on the test report. Include how the issues are resolved Perform As Found Shift Test WI Perform As Found Load Test WI If the scale is found out of tolerance, notify the customer to determine if next calibration date is to be adjusted to other than the schedule. Usually the calibration date is moved up to prove the scale will hold calibration Review the previous maintenance record to see if the scale is scheduled for a deck removal, examination and cleaning. Record on this record when next deck removal is to be done. Establish interval with customer If deck removal is scheduled or required by observation of need, remove the deck. Examine and clean recording any unusual findings Check deck clearance, bumpers, ramps or guards recording observations and repairs For a mechanical indicator, perform Maintenance of Mechanical Indicators WI For a digital indicator, perform Maintenance of Digital Indicators WI For scales with printers, perform Maintenance of Printers WI For scales with load cells, perform Maintenance of Load Cells WI-0028.

20 WI-0041 Portable Floor Scale Maintenance (pg. 2 of 2) Perform As Left Shift Test WI Perform As Left Load Test WI Seal scale and those components which must be secured from unauthorized adjustment. For commercial applications only Instruct scale operating and maintenance personnel of proper operation and maintenance procedures when scale condition or customer indicates a need to Finish the test report, get customer sign-off, sign and distribute Apply scale sticker where it is clearly visible indicating date tested, signature of technician conducting test and date of next calibration Notify state or county Weights and Measures and/or P & S as is appropriate.

21 WI-0042 Bench and Counter Scale Preventative Maintenance (pg. 1 of 2) 1. SOP-010 and SOP-011, Inspection and Testing 1.1 This Work Instruction establishes what Left Coast Scales technicians will perform for tests and what data will be recorded for bench and counter scales as part of a standard preventive maintenance service inspection Review customer file for any special instructions or specific requirements. Include these as steps in this procedure Use the Customer Service Report and Standard Test Report Forms as appropriate as a record of this inspection following Completion of Test Reports WI Record observations and adjustments in the Notes section Consult with scale operator to determine if he has noticed any problems with the scale operation. Record pertinent information as a remark on Test Report. Include how the issues are resolved Inspect load receiver for worn or missing parts. Check overload stops for proper adjustment. Record any pertinent information in the Notes section Perform the As Found and As Left Shift Test Work Instruction WI Perform the As Found and As Left Load Test Work Instruction WI If scale is found out of tolerance, notify customer to determine if next calibration date needs to be adjusted. Usually the calibration date is moved up to prove that the scale will hold calibration For a mechanical indicator, perform Maintenance of Mechanical Indicators Work Instruction WI For a digital indicator, perform Maintenance of Digital Indicators Work Instruction WI For scales with printers, perform Maintenance of Printers Work Instruction WI For scales with load cells, perform Maintenance of Load Cells Work Instruction WI Perform As Left Shift Test Work Instruction WI-0044.

22 WI-0042 Bench and Counter Scale Preventative Maintenance (pg. 2 of 2) Perform As Left Load Test Work Instruction WI Confirm that all required identification markings for load receiver and indicator are in place and legible per H Seal scale and those components which must be secured from unauthorized adjustments (for commercial purposes only) Instruct scale operating and maintenance personnel of proper operation and maintenance procedures when scale condition or customer indicates the need Complete the test report. Review with the customer, get sign-off and distribute Apply scale sticker where it is clearly visible indicating date tested, signature of technician conducting test and date of next calibration Notify state or county Weights and Measures and/or P & S as is appropriate.

23 WI-0044 Shift Test 1.1 This Work Instruction establishes how Left Coast Scales technicians will conduct shift tests for bench, counter and floor scales which do not have sections and the records to be kept The corners of a platform are numbered based on where the indicator is mounted, where the load cell cable or lever exits the platform. Corner 4 is to the left of this point and the rest of the corners are labeled clockwise: Load Cell Cable Weights are placed into the corner as far as possible without overhang ¼ of capacity of the scale is used unless not practical.. When ¼ capacity is not used as much weight as is practical will be used. Record the actual test load used Left Coast Maintenance tolerance for a shift test will be 0.1% of test load or +/-1 division, whichever is greater Zero the scale Place test weights in each corner, record the reading in the shift test diagram. Check yes or no for In Tolerance Without Adjustment Adjust the scale in each corner allowing no more than 1 grad tolerance. Check yes or no for In Tolerance After Adjustment.

24 WI-0045 Load Test 1.1. This Work Instruction establishes how Left Coast Scales technicians will conduct load tests and what data will be recorded for bench, counter and floor scales less than 30,000 lbs. as part of a standard preventive maintenance service inspection. INCREASING LOAD TEST: 2.1. Scale is balanced to or indicating zero A test load equal to 50% of scale capacity must be applied equally distributed across the platform The indicated weight is then posted in the appropriate column next to the applied weght on test report The indicated weight must be within 2/10ths of 1% of the applied load or 1 graduation, whichever is greater (maintenance tolerance) If within tolerance, post N/A in the As Left column of the test report When indicated weights are out of tolerance, adjustments are made according to Left Coast Scales Calibration Procedures published in Installation, Test and Calibration Manuals for the make and model involved. Once adjustments are made, the tolerance becomes 1/10 th of 1% or 1 grad (acceptance tolerance) When adjustments are necessary, this procedure is repeated until the device is repeatedly operating within specifications as outlined in #6 above Apply scale sticker where it is clearly visible indicating date tested, signature of technician conducting test and date of next calibration Notify state or county Weights and Measures and/or P & S as is appropriate.

25 WI-0046 Truck and Railroad Track Scale Maintenance (pg 1 of 2) 1.1 This Work Instruction establishes what Left Coast Scales technicians will perform for tests and what data will be recorded for truck and railroad track scales as part of a standard preventive maintenance service inspection Review customer s file for any special requirements Consult with scale operator to determine if he has had any problems with the operation of the scale. Record pertinent information as a remark on the Truck Test Report Form including how resolved. Complete the Truck Test Report Form per Work Instruction WI Check the condition of the deck. Record observations in the actions taken/remarks section With pit type scales, perform visual inspection per Work Instruction WI Comments and/or pertinent observations are to be posted in the Conditions of section of the Truck Test Report Form With above ground scales, perform visual inspection per Work Instruction WI Comments and/or pertinent observations are to be posted in the Conditions of potion of the Truck Test Report Form For a mechanical indicator, perform Work Instruction Maintenance of Mechanical Indicators WI For a digital indicator, perform Work Instruction Maintenance of Digital Indicators WI for scales with printers, perform Work Instruction Maintenance of Printers WI For scales with load cells, perform Work Instruction Maintenance of Load Cells WI After visual inspection of all components is complete, scale is ready for testing. Use the Truck Test Report Form Perform As Found Shift Test Work Instruction WI Perform As Found Load Test Work Instruction WI If scale is found out of tolerance, make adjustments to correct and retest. Notify customer

26 WI-0046 Truck and Railroad Track Scale Maintenance (pg 2 of 2) to determine if next calibration date is to be adjusted to other than the schedule. The calibration date could be moved up to prove the scale will hold calibration If scale is in tolerance, the As Left shift and load test portion the Truck Test Report Form must be completed recording same information as posted in the As Found shift and load test. If out of tolerance and adjustments are made to restore accuracy the final weight readings are posted as the final test results Seal scale and those components which must be secured from unauthorized adjustments Instruct scale operating and maintenance personnel of proper operation and maintenance procedures when scale condition or customer indicates the need Finish the Truck Test Report Form. Review with customer and get sign-off and distribute Apply scale sticker where it is clearly visible indicating date tested, signature of technician conducting test and date of next calibration Notify state or county Weights and Measures as is appropriate.

27 WI-0048 Visual Inspection of Scale Pits and Lever Systems for Truck and Track Scales 1.1 This Work Instruction establishes what Left Coast Scales technicians will do during a visual inspection of truck and railroad track scale pits as part of a standard preventive maintenance service inspection Remove manhole covers and enter pit to check the following: Pit condition (integrity of concrete, accumulation of dirt, water, etc.). Check operation of sump pump or clearance of natural drain as applicable. Grease condition on moving parts. Should be packed and relatively clean. Obvious wear problems on suspension system, pivots and bearings and to assure parts are in proper place and hanging plumb and level. Visually inspect condition of steel (report on rust, damage, etc.). Check bumper bolts for proper installation and adjustment (should have 1/8 clearance and be adjustable yet secured in place). Defective bumper bolts must be repaired. This is normally handled as a quoted repair job that customer must approve For full electronic scales, load cells and cables are checked per Work Instruction WI On railroad track scales, the condition of the approaches and approach rails must be checked and verified to be okay. Approach rails should have a minimum of 3/8 and a maximum of ½ clearance between them and live rail Check deck on mechanical scales for proper oscillations. Deck should be free and oscillate 3 to 5 times before settling down. If it oscillates too much, bumper bolts may need adjusting Rigid checking systems should be visually checked to make certain they are properly aligned and secure and are not causing unwarranted friction Pertinent comments regarding condition of above items is to be posted under Condition of section on the Truck Scale Test Report Form and reviewed with the customer.

28 WI-0049 Visual Inspection of Above-Ground Truck and Track Scales 1.1 This Work Instruction establishes what Left Coast Scales technicians will do during a visual inspection of above-ground truck and railroad track scales as part of a standard preventive maintenance service inspection Visually check deck and approaches for damage Visually check ends, sides and surface area under deck for foreign matter. Remove any obstructions. Report major problems (i.e. cleaning jobs) to customer in the comments section for follow-up corrective actions Visually check load cells and cabling per Work Instruction WI Check deck on mechanical scales for proper oscillations. They should oscillate 3 to 5 times before stopping Rigid checking systems should be visually checked to make certain they are properly aligned and secure and are not causing unwanted friction.

29 WI-0050 Shift Test for Truck and Track Scales 1.1 This Work Instruction establishes how Left Coast Scales technicians will perform as found and as left shift tests on truck and railroad track scales and what data will be recorded on the Truck Scale Test Report Form as part of a standard preventive maintenance service inspection Truck Scales - The shift test is normally done with a Heavy Capacity vehicle weighing at least 20,000 lbs. This vehicle s rear axle is placed over the sections first in one direction then the other and the weight is recorded under the appropriate section under shift test results on the Truck Scale Test Report Form. Errors greater than 1/10 th of 1% must be adjusted out and the test repeated until such time as scale is weighing and repeating within 1/10 th of 1% of the gross vehicle weight of the test truck and its weights. The as left section of the Truck Scale Test Report Form is then completed by posting the final weight reading by section Railroad Track Scales These scales are tested in the same manner except the railroad or WWIB provides the 100,000 lb. test car. The inspector conducts the test to meet or exceed H44 standards then completes the test report accordingly. The Left Coast Scales technician provides assistance and makes adjustments as required bringing scales with tolerance. Errors greater than 1/10 th of 1% must be adjusted out and the test repeated until such time as scale is weighing and repeating within 1/10 th of 1% of the gross vehicle weight of the test truck and its weights. The as left section of the Truck Scale Test Report Form is then completed by posting the final weight reading by section.

30 WI-0051 Load Test for Truck and Track Scales References 1.1 This work instruction establishes how Left Coast Scales technicians will perform as found and as left load tests on truck and railroad track scales and what data will be recorded on The Test Report as part of a standard preventive maintenance service inspection. 2. Procedure 2.1 Truck Scales: Calibrated test weights are applied in thousand pound increments on one or more sections and recording actual readings as well as the error, if any, in the as found load test section of the Test Report If no errors are found, the same information is posted in the as left load test section of this test report and the test report completed If errors are found, adjustments are made to correct the error and reduce to zero or within 1/10 th of 1% or 1 graduation whichever is greatest. This information is then posted as the as left load test section of this test report and the test report completed. 2.2 Track Scales: Railroad track scales are tested with the railroad's or WWIB, 100,000 lbs. test car. The inspector and/or technician conducts the test to meet or exceed H44 standards then completes the test report accordingly. The technician provides assistance and makes adjustments as required to bring scales within tolerance If no errors are found, the same information is posted in the as left load test section of this test report and the test report completed If errors are found, adjustments are made to correct the error and reduce to zero or within 1/10 th of 1% or 1 graduation whichever is greatest. This information is then posted in the as left load test section of this test report and the test report completed.

31 WI-0052 Tank and Hopper Scale Maintenance (pg. 1 of 2) 1.1 This work Instruction establishes what Left Coast Scales technicians will perform for tests and what data will be recorded for tank and hopper scales as part of a standard preventive maintenance service inspection Review customer s file for any special requirements to be performed Use the Tank Scale Test Report Form as a record of this inspection following Work Instruction for Completion of Test Report WI Record observations, repairs, and recommendations in the actions taken/remarks section Consult with scale operator to determine if he has any problems with the operation of the scale. Record pertinent information in the remarks section, including how the issues are resolved Perform a visual inspection of the lever system per Work Instruction WI For a mechanical indicator, perform Work Instruction Maintenance of Mechanical Indicators WI For a digital indicator, perform Work Instruction Maintenance of Digital Indicators WI For scales with printers, perform Work Instruction Maintenance of Printers WI For scales with load cells, perform Work Instruction Maintenance of Load Cells WI Conduct tests using known weights and adjust as necessary to conform to performance requirements and tolerances in NIST H Confirm that all required identification markings for the load receiver (tank or hopper lever system) and indicator are in place and legible per NIST H Seal scale and those components which must be secured from unauthorized adjustment Instruct scale operating personnel of proper operation and maintenance procedures when scale condition or customer indicates a need Complete the Tank Scale Test Report Form. Review with the customer, get sign-off and distribute.

32 WI-0052 Tank and Hopper Scale Maintenance (pg. 2 of 2) Apply scale sticker where it is clearly visible indicating date tested, signature of technician conducting test and date of next calibration Notify state or county Weights and Measures as is appropriate.

33 WI-0054 Visual Inspection of Load Receiver on Tank and Hopper Scales 1.1 This Work Instruction establishes what Left Coast Scales technicians will do during a visual inspection of the load receiver on tank and hopper scales as part of a standard preventive maintenance service inspection Visually inspect load receiver for obstruction and foreign matter that could cause friction Visually inspect linkage and suspension to see that it s properly aligned and plumb Visually check all hardware to see that it s secure and installed as designed Visually check gates and/or boots on hopper scales and any rigid pipes connected to tank scales to see that they are not binding or causing friction Visually inspect checking system to see that it allows for some movement (1/8 ) and is not binding Visually inspect supports to be sure they aren t damaged or deflecting so as to cause weight errors Check repeatability and balance to zero.

34 WI-0055 Testing Tank and Hopper Scales 1.1 This Work Instruction establishes how Left Coast Scales technicians will test tank and hopper scales as part of a standard preventive maintenance service inspection The indicating device must be balanced at zero and repeating or holding zero The device should be tested up to 50% of its capacity, or to its normal use range, using a test load or a combination of weights and material Test weights equal to 25% of capacity for devise capacities of 301 to 3000 pounds will be applied equally on the corners. The weights applied as well as the indicated weight and any errors must be reported on the Tank Scale Test Report Form in the as found section. If adjustments are necessary to eliminate errors, this test is repeated until there are no errors greater than 1/10 th of 1% of the applied load and the results posted in the as left section Test weights equal 12 ½% of capacity, for devise capacity of 3,001 to 40,000 lbs. will be applied equally on the corner. The weights applied as well as the indicated weight and any errors must be reported on the Tank Scale Test Report Form in the as found section. If adjustments are necessary to eliminate errors, this test is repeated until there are no errors greater than 1/10 th of 1% of the applied load and the results posted in the as left section Build-up tests, using known weights coupled with equal amounts of material should be conducted on scales where the capacity warrants it. This is done in steps, first applying the weights and recording the reading in the as found strain test section, then removing the weights and applying materials equal to the indicated weights, then reapplying the weights, taking a reading and posting the error, if any, as well as the tolerance. This step is repeated until we reach at least 50% of the scale s rated capacity or its nominal operating range. If adjustments are necessary, this entire procedure must be repeated until such time a device tests and repeats within H44 tolerance.

35 WI-0057 Fine Increment and Counting Scale Maintenance (pg. 1 of 2) 1.1 This Work Instruction establishes what Left Coast Scales technicians will perform for tests and what data will be recorded on fine increment and counting scales as part of a standard preventive maintenance service inspection Review customer files for any special instructions or specific requirements Use the Standard Test Report Form as a record of this inspection following Work Instruction WI-0058 for Completing the Standard Test Report. Record observations and adjustments in the action taken section Consult with scale operator to determine if he has noticed any problems with the scale operation. Record pertinent information as a remark on the Standard Test Report. Include how the issues are resolved Do a visual inspection of the equipment. Inspect load receiver for broken or missing parts. Check for any obstructions. Check overload stops, if applicable, for proper adjustment. Make sure scale is level and secure. Record any pertinent information in the action taken/remarks section Perform As Found and As Left Shift Test Work Instruction WI Perform As Found and As Left Load Test Work Instruction WI If scale is found out of tolerance, technician must review with customer to determine if next calibration date needs to be adjusted. Usually the calibration date is moved up to prove that the scale will hold calibration for a shorter period of time Confirm that all required identification markings for load receiver and indicator are in place and legible Seal Scale and those components which must be secured from unauthorized adjustments Instruct scale operating and maintenance personnel of proper operation and maintenance procedures when scale condition or customer indicates the need Complete the Standard Test Report Form. Review with the customer, get sign-off and distribute Apply scale sticker where it is clearly visible indicating date tested, signature of

36 WI-0057 Fine Increment and Counting Scale Maintenance (pg. 2 of 2) technician conducting the test and date of next calibration Notify state or county Weights and Measures when appropriate.

37 WI-0058 Completing the Standard Test Report for Fine Increment and Counting Scales 1.1. This Work Instruction details how Left Coast Scales technicians will complete the Standard Test Report for as a routine test on fine increment and counting scales as part of a standard preventive maintenance service inspection See WI-0043 and WI-0043A Completing the Standard Test Report Form.

38 WI-0059 Shift Test for Fine Increment and Counting Scales 1.1. This Work Instruction establishes how Left Coast Scales technicians will conduct shift tests for fine increment and counting scales which do not have sections and the records to be kept as part of a standard preventive maintenance test list and calibration inspection The corners or quadrants of a platform are numbered based on where the indicator is mounted and where the load cell cable or lever exits the platform. Corner 4 is to the left of this point and the rest of the corners are labeled clockwise: Load Cell Cable Weights are placed in each corner or quadrant as far as possible without overhang and the indicated weight is recorded in the as found section At least 25% of the capacity of the scale is used unless not practical. When 25% capacity is not possible, use as much weight as is practical. Record the actual test weight used. Remove test weights after each corner test to assure that the device returns to zero Maintenance tolerance for a shift test will be 0.2% of 1% of the test load. If the corners or quadrants are within maintenance tolerance or 1 graduation of each other, no further tests are necessary. If the corners are out of tolerance, they must be adjusted per engineering specifications to bring them into tolerance. These readings are then posted in the as left column.

39 WI-0060 Load Test for Fine Increment and Counting Scales 1.0 Scope: 1.1 This Work Instruction establishes how Left Coast Scales technicians will conduct load tests and what data will be recorded for fine increment and counting scales as part of a standard preventive maintenance service inspection. 2.0 Procedure: 2.1. Scale must be balanced at zero Certified test weights equal to at least 50% of scale capacity must be applied equally distributed on platform Each time a test weight is placed on the platform, the indicated weight is posted in the as found column next to the applied weight on the test report The indicated weight must be within 2/10 th of 1% of the applied load to meet maintenance tolerance requirements If within tolerance, N/A will be posted in the as left test column of the test report When indicated weights are out of tolerance, adjustments are made according to Left Coast Scales calibration Procedures published in Installation, Test and Calibration Manuals for the make and model involved. Once adjustments are made, acceptance tolerance must be met which is 1/10 th of 1%. 27. When adjustments are necessary, this Work Instruction is repeated until the device is repeatedly operating within tolerance.