Flintec DSB7-7.5T Feuille d'instructions

MSB Flintec 26 November 2014

These guidelines provide guidance for the safe installation and operation of Flintec load cells.

Installations should be carried out by suitable qualied engineers.

Please read this manual carefully.

Chassis-body mounted

on board weighing load cells

Trucks, Agricultural Machines

and Axle Weighbridges

DSB7 7.5t & 15t Load Cell

Installation guidelines For use onboard trucks and machines

7.5 Tonne (16500 Lbs) capacity

15 tonne (33000 Lbs) capacity

MSB Flintec 26 November 2014

Contents

1. Introduction&Weighingsystemoverview

2. Accuracy,Performance&Applications

3-4. Installationstyles

4. Cableorientation

5. Preparation

6-10. Body-ChassisAlignment&Installation

11. Weldingprocedure

12. Torquevaluesandxingselection

13. Installationexamples,axle,sidebody-railmount

14. Technicalspecicationanddimensions

15. Cable,connectorsandcableinstallation

16. Routinemaintenance&Installationchecklist

MSB Flintec 26 November 2014

Introduction

Disclaimer

Wereservetherighttomakechangestotheproductscontainedinthismanualinordertoimprovedesign,performance

andreliability.

Theinformationinthismanualisbelievedtobeaccurateinallrespectsatthetimeofpublication,butissubjectto

changewithoutnotice.Flintecoritsdistributorsassumesnoresponsibilityforanyconsequencesresultingfromtheuse

oftheinformationprovidedherein.

TheFlinteconboardmountedloadcellisahighlyadvancedelectronicmeasuringdevice.Weightismeasuredbyload

cellsinstalledbetweenthebodyandthechassis.Theseruggedloadcellsarestrongenoughtoprovideyearsofreliable

service,yetaresensitiveenoughtodetectachangeinweightofjustafewkilos.Duetodifferencesfromapplication

toapplicationtheremaybesomesignicantassemblyvariations.Theinstallationprocessisvirtuallythesamewhether

itisbeingperformedasaretrotortoanewvehicleormachine.Itisextremelyimportanttofollowtheseinstallation

guidelinesandusethespeciedmaterialstoensurethatthecompletedassemblywillmaintainitshighstrengthfor

maximumsafety.Itwillalsoresultinminimuminstallationcosts,highaccuracyandlonglifeforyourweighingsystem.

WARNING

Failuretofollowtheseinstructionscouldcauseahazardousoperatingcondition.Uponcompletionoftheloadcell

installation,youoranappropriatelytrainedserviceengineerwillneedtoinstallaweighingindicatorandcalibratethe

system;Calibrationissimplyanelectronicadjustmentofthescaletocompensateforminuteinstallationvariations.

Completeinstructionsfortheseprocedurescanbefoundintheweighingindicator'soperator’smanual.

Installationmustbeinaccordancewithnationallawsandregulations.Aninstallationchecklisthasbeenprovidedinthe

backofthismanual.Pleaserefertoitduringinstallationandcheck-offtheimportantstepsastheyarecompleted.

Weighing system overview

Flinteconboardweighingsystemsareidealforindustrialweighingapplicationsandsuitableformeasuringeithergross

vehicleweightorthenetweightofcargobeingloadedordelivered.Thebasicsystemconsistsofload-supporting

transducers(loadcells)andanelectronicmeter(weighingindicatorordisplay)capableofbeingcalibratedtodisplay

theweightinconvenientlbsorkgs,electricalcablingconnectingtheloadcellsandindicator:seediagrambelow.

FRONTNEARSIDELoadcell REAROFFSIDELoadcell

Truckbody

FRONTOFFSIDELoadcell REAROFFSIDELoadcell

JunctionBox

4,60r8PortsAvailable

WeighingIndicatororCPU

vehiclemanagementsystem

InputChannel1

AnalogueLoadCells

PowerInput

Typically9-30VoltsDc

FromIgnitionSystem

Typicalfourcell

arrangement

Typically4,6or8DSB7cellsarefttedto3.5-50tonnesgrossweightvehicles.

MSB Flintec 26 November 2014

Applications

Installationsaretypicallyaccomplishedbyseparatingthebodyframefromthechassisortrailerframeandinstalling

loadcellsbetweenthesetypicalvehiclestructures;

Accuracy and Performance

ThismanualisprimarilyconcernedwiththemechanicalinstallationoftheFlintecDSB77.5tonne(16500Lbs)and

15tonne(33000Lbs)capacitytruckloadcellsandcables.Pleaserefertotheappropriateoperator'smanualforthe

installationanduseoftheindicator.Optimumonboardweighingperformanceisobtainedwhentheloadcellsare

installedbetweentheload-carryingbody(compactorbody,tipperbody,box,tank,atbed,etc.)andthevehiclechassis

andcarryingtheentireweightofthesuperstructureandpayload.Noweight-supportingstructureotherthantheload

cells,suchasbracesorgussetsshouldattachthesuperstructuretothechassis;thiswillresultinanalternateload-path

thatwilldegradeweighingsystemaccuracy.Typicalapplicationsinclude:wastetrucks,tippers,tankers,atbedsand

vantypestructuresmountedoneithertruckchassisortrailers.Truckbodiesandpayloadsaresupportedabovethe

chassiswithloadcellsmounteddirectlytothetruckframe(seeexampleillustrationsbelow)areusuallyaccomplished

byseparatingthesuspensionsubframefromthetrailerframeandinstallingloadcellsbetweenthesestructures.

Tipping Trailer

Under-bodytippingarrangement

Tipping Trailer

Frontendtippingarrangement

Loadcell

Loadcell Loadcell Loadcell

Chassis

4 Axle Rigid Fixed Body

Waste/Garbagetruck,boxedtruck

Loadcell Loadcell

Chassis

2/3 Axle Rigid Fixed Body

Waste/Garbagetruck,boxedtruck

Loadcell Loadcell

Chassis Chassis

Loadcell Loadcell

4 Axle Rigid Tipping Body 2/3 Axle Rigid Tipping Body

Loadcell

Agricultural machines

Loadcell

LoadcellLoadcell

Agricultural machines

MSB Flintec 26 November 2014

Installationstyles

Mounting Styles:

Twobasicmountingstylesareusedforinstallingchassismountedonboardweighingloadcells:thein-linemountand

theout-boardmount.

Out-board mounted load cell

Anout-boardmountedloadcellisinstalledalongsidetheframemembersusingbracketslocatedout-boardofthechassis

andbodyframerails.Shownherearebothboltedandweldedmethodsofattachmentthetop&bottomloadcellbrackets.

Bodysuperstructure

framemember

Chassissuperstructure

framemember

Mountingangles

(providesadditional

strength)

Spreader/coverplate

Topwelded

mountingbracket

Bottomwelded-on

mountingbracket

Topbolted

mountingbracket

In-line mounted load cell

Anin-linemountedloadcellisinstalledbetweentheangesoftheupperbody-railandlowerchassisframeandalignedwith

thoseframemembers.Loadspreadingplates,sometimescalledcoverplates,sh-platesoranglesectionsarefrequently

usedtospreadtheloadoveragreaterarea.Achassisorbodysubframemayberequiredwherethebodyispronetoexing.

Bottombolted-on

mountingbracket

Chassissuperstructure

framemember

Bodysuperstructure

framemember

Framestiffener

(gussetorrib)

MSB Flintec 26 November 2014

Considerationssuchasavailablespace,tyreclearanceandrestrictionsforoverallvehicleheightwillgenerally

determinewhichmountingstylewillbeused.Thefollowingchartillustratesthefeaturesofeachmountingstyle:

Themostcommonpositionforloadcellmountingistopositiontheloadcellsothatthespacerblocksareunderneath

theloadcell.However,installationcansometimesbesimpliedbyinvertingtheloadcellandinstallingwiththebearing

platesabovetheloadcell,especiallywhencombinedwiththeoutboardmountingstyle.Anairgapisrecommendedto

preventthebuild-upofdebrisbeneaththeloadcell.

Cable Orientation

Theloadcellcanbeorientatedsothatthecableconnectorislocatedoneithertheoutboardorinboardsideofthe

loadcell.Outboardlocatedcableexitisgenerallymoreaccessibleforinstallationandservice,butmayneedacover

plateforprotectionfromroaddamage.Inboardfacingcableexitprovidesimprovedprotectionforthecable.Outboard

mountedloadcellsgenerallyhavelimitedaccessforinboardfacingcableexit.Forthisreason,inboardfacingcablingis

usuallyusedonlywithin-linemountedloadcells.Connectorprotection;Flintecrecommendsthataprotectivecoverbe

providedtoprotectoutboardfacingconnectorsfromroaddamagesuchasyingstones.

In-line mounting Outboard mounting

Used when outboard clearances or suspension systems means

space is limited Requires space for load cell installation outboard of chassis

Requires only one mounting bracket per load cell Requires an upper and lower mounting bracket per load cell

Will raise the overall vehicle height by approx. 50 mm (2.0") unless

frame is recessed Will raise the overall vehicle height by approx. 15-20 mm (5/8"-3/4")

Mounting holes for the load cell must be added to the body frame

structure Load cell mounting holes are located in the mounting brackets

Allows for either inboard or outboard facing cable connectors Outboard facing cable connector is usually required

Out-boardfacing

cablegland

In-boardfacing

cablegland

Typicalbolted-oninstallation.

Anall-weldedinstallationisalso

possible-bothattachmentmethods

areapplicationspecic.

Typical installations.

Don'tallowbolts

toprotrudehere

Minimumairgap:

7.5t=6mm(1/4")

15t=10.00mm(3/8")

MSB Flintec 26 November 2014

Loadcellmountingbracketsareattachedtothesuperstructurebymeansofweldingorbolting.Inordertoprovideforthe

mountingofloadcellsandmountingbrackets(illustratedinlatersections),somemodicationtothesuperstructuremay

berequired.Themodicationsmaybeassimpleasprovidingaatsurfaceforbracketweldingormaybeasextensive

asprovidingarecessintheunderframeforthemountingoftheloadcells.

Modicationtothesuperstructurewillvaryaccordingtothespecictypeofinstallationtobeperformed;whetheritis

foratrailersuspensionsubframeassemblyorfortruckframemountedsystemssupportingentirepayloadcarrying

superstructures.Outboardmountedloadcellsmayonlyneedspacetoweldorboltloadcellmountingbrackets,whileanin-

linemountedloadcellsystemwillneedholesdrilledintheunderframeofthesuperstructurefortheloadcellmountingbolts.

Whenevermakingmodicationstoastructure,caremustbetakentoprovideforboltstrengthandrigidity(stiffness)for

thenishedinstallation.Everystructurewilldeform(bend,twistorsag)toacertaindegreewhencarryingaload.The

installermustensurethatthemodiedstructureisstrongenoughtopreventnotonlypermanent(elastic)bendingso

thatupperstructuralelementswillnotcontactlowerelementsandcreateanalternativeloadpatharoundtheloadcells.

Excessiveframebendingcanbepreventedbyeitheraddinga‘glove’(astructuralsupportingsleeve)totheframe,orby

addingadditionalloadcellsinthatareaformoresupport.

Frame Stiffeners:

Iftheframesectionabovetheloadcellisanopensection,suchasachannelor‘I’beam,webstiffenersarerequiredto

avoidframetwist(seeillustrationbelow).Thestiffenersarelocatedneartheendsofeachbearingplateforinvertedload

cellmounting,orbetweenthemountingholesforloadcellsinstalledwiththebearingplatesbeneaththeloadcells.

Recess Mounting:

Oftenthemostpracticalmethodforinstallingon-boardframemountedscales(particularlywithanin-linemounted

system)withoutanundesirableheightincreaseofthetrailerorbody,istoprovidearecessinthesuperstructureunder

frame.Ageneralrecommendationforthisapproachisshowninthefollowingillustration.Theinstallershouldassurethat

anymodiedstructurewillretainthestrengthandstiffnesspropertiesoftheoriginalstructure.

Preparation

Framestiffeners

(ribsorgussets)

10mm(3/8")thick

Coverplateorglove

10mm(3/8")thick

Flange20mm(0.75")thick Don'tallowbolts

toprotrudehere

MSB Flintec 26 November 2014

Body-chassisalignment

Flintecloadcellsaredesignedtobeinstalledbetweenthebodyandchassisofindustrialtrucks.Itisimperative

theloadcellsareinstalledin-linewiththechassisandbodyrailswithnomisalignmentortwistingforces

projectedontotheboltsorfixings.

Alignment:

Becausetheinstallationofloadcellsinvolvestheseparationofthebodysuperstructurefromthesupportingchassis

frame,caremustbetakentoensuretheseparatedelementsareinstalledandinalignment;newbuildorretrots.The

bodymustsitatandloadcellmountingbolt-holesalignwithouttheuseofadditionaltools.e.g.jemmybarsorjacks.

Boltsshouldbeinsertedbyhandandscrewedbyhandpriortonaltighteningwithatorquewrench.

Markingtherelativepositionsontheframeelementsbeforeassemblyisaneffectivemeansofassuringproperalignment.

Alsoensurethestraightnessofframeelementswhencuttingorweldingtopreventundesirablebendingorwarpingduring

assembly.Theuseofasimpleframestiffener(rib,gussetorstiff-back),weldedintoplacepriortomodication,iseffective

forthispurpose.

Mounting Structure:

OptimumperformanceofDSB7isdependentuponasolidmountingbasefortheloadcells.Steelbracketsof

heavyconstructionarerequired.Sincethisisathickersectionthanusuallyfoundontrucks,acoverplatemaybe

necessarytoevenlydistributeforcestoavoidstressconcentrationsandpossiblecrackinginthethinnersectionsofthe

superstructure.Locatingloadcellsintheimmediatevicinityofcrossmembersorotherframestrengthening/stiffening

elementstoprovidemaximumsupportisalsoimportantforprovidingastructurallysoundinstallation,aswellasa

reliableon-boardweighingsystem.Whenseparatingand/oraligningthebodytothesupportingchassisframe,be

carefulwhenre-routinghoses,airlines,fuellinesetc.Someoftheseitemsmayneedtobereplacedbylongeronesto

preventsecondaryloadpathswhichcausepoorweighingperformance.

Theseitemsarealsosusceptibletodamageiftheyarenotofsufcientlengthtoallowforframeseparationorarenot

properlyprotectedatinstallation.Uponcompletionoftheinstallation,lookcloselyatalltheelementsofthemechanical

installationtoavoidproblemswithpinchedwires,rupturedhoses,etc.,especiallyduringtherstoperationofany

movingstructuresuchasadumpbody.

Topmountingbracket

Spreaderplate

Bodyrail

Pocketweld

Bracket welded to chassis example

MSB Flintec 26 November 2014

Loadcellmountingbracketinstallationmethodsdifferdependinguponwhetherthesupportingstructureisatruck

chassisoratrailersuspensionsubframe.Truckchassisframesaremanufacturedfromheattreatedhighstrengthsteel,

requiringloadcellmountinganglesorbracketstobeboltedtotheseframes.Trailersubframeshowever,arenotheat

treatedandmountingbracketscanbeweldedtotheseframes.

CAUTION:Reviewtruckortrailerbodyorchassismanufacturer’srecommendationsbeforeweldingtoframe.

Bolting Requirements:

Thestructuralrequirementsfortheloadcellmountingbracketsareaffectedbytheactualweightbeingsupportedby

theloadcellsandbydynamicservicefactorscausedbyroadconditions.Boltedload-carryingbracketsaresusceptible

toslippageifthepropernumberofboltsarenotusedoriftheboltsarenottightenedtotherecommendedtorque.Use

thefollowingcharttodeterminethepropernumberofboltsforboltedinstallations.Refertothechartonpage12forthe

recommendedtorquevalueswhentightening.

Forin-lineinstallations,usetheboltingrecommendationsforhighwayuseregardlessofroadcondition.

FrameRailInspection:Inspecttheframerailstoensuretheyareclean,straightandfreeofcracks,corrosion,pitting,burrsor

anyotherimperfectionsthatmayaffecttheinstallationandtofthemountingangles/brackets,orthestrengthoftheframe.

MountingBracket/AngleInstallation:Setthemountingangles(forin-lineinstallations)ormountingbrackets(foroutboard

installations)inplaceontheframerails.Determineifandwheretheymustbecutorcontouredtoallowclearancefor

existingbolts,rivets,springhangers,etc.,ontheframe.Marktheselocationsonthemountingangles/brackets,allowing

foraminimum25mm(1")radius-nosharpcorners.Removeangles/brackets,trimasrequired,andgrindedgessmooth.

NOTE:Itisnotnecessarytocutoutloadcellmountinganglesandbracketsforeasilyremoveditemssuchasfueltanks,

batteryboxes,etc.Theseitemsaresimplyrepositionedorspacedouttoconformtotheaddedthicknessoftheloadcell

mountingangles/brackets.

Numberofboltsused

-Topand

Bottombrackets

Maximumloadonloadcells-

normalhighwayuse

DSB77.5t

(16500Lbs)

M12-1.75

DSB77.5t

(16500)

1/2"(0.5")

DSB715t

(33000)

M16-2

DSB715t

(33000)

1/2"(0.5")

3 5,000kg 11000Lbs 5,000kg 11000Lbs

4 7,500kg 16500Lbs 10,000kg 22000Lbs

5 7,500kg 16500Lbs 15,000kg 33000Lbs

6 N/A N/A 15,000kg 33000Lbs

MSB Flintec 26 November 2014

Clampthemountingangles/bracketstightlytotheframe.Besurethattheclearancesandcut-outsarecorrect.Locate

anddrillholespertherecommendationsinthechartonthepreviouspageandbracketdrawingsinthexingsectionon

page12ofthismanual.

NOTE:

Boltholesinmountingstructuresmustbedrilled,notburned.Holesshouldnotbeoversizedmorethan1mmtoensure

asnugtforbolts.Useaminimumofboltsaccordnigtotheguideonpreviouspagepermountingangleorbracket.

Alsolocateboltswithin25mmto38mmofeachendofthemountingangle/bracket.Dothesamefortheedgeofeach

cutoutdeeperthan25mm.

Attachthemountingangle/bracketusingBS/ISO/DINGrade10.9(SAEGrade8)qualitybolts,GradeClocknutsanda

hardenedwasherundereachlocknut.TheboltsmusthaveadiameterofM16(5/8”)minimumfor15tcellsandM12(3/8")

for7.5tcellsandsufcientlengthtoprovideaminimumof3threadspasttheendofthelocknut.Tightenallboltstothe

propertorquevaluelistedinthetableonpage12.Whenweldingbracketstonon-heattreatedframes,usealowhydrogen

processandAWSE7018rodorequivalent.Checkthelengthsofallconnectionsforitemsthathavebeenmovedduring

theinstallationofthemountingangles/brackets.Theseconnectionsmayincludebatterycables,fuellines,airlines,and

electricalcables.

Framemountingbolts

Chassisframe(rail)

Out-board installation

In-line installation

Ce manuel convient aux modèles suivants

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