Flintec DSB7-7.5T Instruction sheet

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.
1
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
2
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
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
3
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
4
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
5
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.
6
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.
7
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.
8
Framemountingbolts
Chassisframe(rail)
Chassisframe(rail)
Out-board installation
In-line installation

MSB Flintec 26 November 2014
Assembleuppermountingbracketstotheloadcellsusingthexingkitswhereprovided,(forin-linemountedsystems
wheretheloadcellsboltdirectlytotheupperframestructure,simplymounttheloadcellassembliestotheupper
frame).Makesurethexingsaretheproperlengthanddonotbottomoutinthetappedholes.Ifthemountingboltsare
toolong,damagetotheloadcellsispossible.Adangerousoperatingconditioncouldexistiftheboltsarenotsecure.
Placetheloadcellassembliesonthevehicleframemountingbracketswhichwereinstalledin‘FramePreparation’.
Adjusttheloadcellassembliesintotheirnalposition,verifyingtandclearanceswiththesuperstructure.Boltor
welduppermountingbracketsecurelytothesuperstructureusingalowhydrogenprocessandAWSE7018rodor
equivalent(DONOTWELDBEARINGPLATESYET).See‘CAUTION’onpage10beforeproceedingwithwelding.Lift
thesuperstructureandremovethetemporaryspacers.
Theloadcell/uppermountingbracketassembliesarenowreadytobeinstalledonthesuperstructure.Todothis,place
temporaryspacersusually20mmto25mm(3/4"-1")onthevehicleframetoprovidetheproperspacingbetweenthe
superstructureandthevehicleframe.Lowerthesuperstructureontothesespacers.Besuretocheckthesuperstructure
forproperalignmentwiththevehicleframe.
Weldassemblytobodyframealong
threesides&plugweldthroughholes
Uppermountingbracket
(outboardmount)
Topmountingbolts
Temporaryspacerblock
9
Spacerblocks
(seepage14fordimensions
-squareplateissufcient)
Loadcelluppermounting
bracketassembly-
(weldedorbolted)

MSB Flintec 26 November 2014
Thesuperstructurewiththeloadcellassembliesattachedisnowreadytobesecuredtothevehicleframemountingand
angles/brackets.Lowerthesuperstructuresothattheloadcellbearingplatessitintheproperpositiononthevehicle
framemountingangles/brackets.Checktheproperalignmentbetweenthesuperstructureandthevehicleframe,and
checkallbearingplatesforcontactwiththeframemountingangles/bracketsshimanygapsgreaterthan1.5mm(1/16").
Caution:
BearingPlateWelding:Pleasereadtheweldingproceduresonthefollowingtwopagescompletelybefore
proceeding.Theweldingofthebearingplatesisthemostcrucialstepintheinstallationprocess.
Takeprecautionstoensurethatthevehicleelectricalsystemisnotdamagedbythewelding.Topreventelectrical
currentowthroughtheloadcell,attachgroundstrapdirectlytothestructureonthesamesideoftheloadcellon
whichweldingisbeingdone.
Completetheattachmentofthesuperstructure/loadcellassemblyinthefollowingorder(inaccordancewiththe
weldingproceduresonpage11):
1. Tackweldthebearingplatestothemountinganglesorbrackets.
2. Removetheslagfromtacksand‘feather’endoftackwithagrindertoprovideasmoothtransitionfortheroot
 topassasitpassesthroughthetack.Weldingcanbecompletedwithoutdisassemblyofloadcellsfrombearing
 plates.Directelectrodeawayfromunprotectedundersideofloadcell.
3. Alternateweldsfromside-to-sideandend-to-endtoavoidwelddistortion.
10
Chassisframerail
framemember
Weldloadcellbracketsinplace(seecaution
below,andweldingprocedureonpage11before
proceedingwithwelding)
Bodysuperstructure
framerail
Bottomwelded-on
mountingbracket
Topbolted
mountingbracket
Bracket welded to chassis example

MSB Flintec 26 November 2014
Weldingprocedure
Thefollowingprocedureguidesthewelderthroughtherecommendedproceedureforweldingbracketsandbearing
platestoframemembers.
WARNING:Allwelding,metalworking,andassemblymustbeperformedbyaqualiedpersonusingpropertoolsand
safeworkhabits.Whenwelding,useaprocedurethatassuresasound,goodqualityweld.Overweldingmaycause
distortionanddamage;underweldingmaynotdevelopsufcientstrength.
CAUTION: Takeprecautionstoensurethatthevehicleelectricalsystemisnotdamagedbythewelding.Attachground
strapdirectlytovehicleframemember(notloadcellbody)towhichthebearingplatesarebeingweldedtoprevent
electricalowthroughloadcell.
Welding Process:UsealowhydrogenprocessandAWSE7018rodorequivalent.Thebearingplatemaybewelded
usingSMAWstick,GMAWspraytransfer,orFCAW.TheusershouldnotuseGMAWshortcircuittransfer.
WeldConguration:Thebracketplatesshallbeattachedusingasingleormultipasslletweldsequence
DepositedWeldMetalFilletSizes:Thenishmultipasslletassemblyshallbeaminimumof8mm(1/3”).
Preheat:Thebearingplateandthebasemetalmountingsurfaceshallbewarmedinpreparationforweldingto
reduceshrinkagestress.Anysuitabletorcharrangementissatisfactory.Spotheatingshallbeavoided.Thepreheat
temperatureshallbeaMINIMUMof20°C(68°F)andaMAXIMUMof65°C(150°F).
Cleaning Before Welding:
Bracketcomponentsandbearingplatesshallbevisuallyinspectedtoverifythatthereisnooil,grease,dirt,paintorother
foreignsubstancethatwillreducetheweldquality.Weherebracketsareweldedtothebodyand/orchassis,mounting
surfacesshouldbepreparedusingandanglegrinderorpowerwirebrushtoremoveallpaint,primer,orothersurface
coating.Anareathesizeofthebearingplateplus25mm(1")shouldbecleanedandgroundtobarebasemetal.
In process Cleaning:
Eachlletshallbevisuallyinspectedwithallslagcoverremoved,beforeproceedingwiththenextbead.Astiffwire
brushorneedlescalermaybeusedforslagremoval.
Final Inspection:
LongservicelifedependsonqualityapplicationofthelletweldsandTHEFINALSIZEOFTHEFILLET.Thereshall
benoundercutoneithertheupperleg(onthebearingplate)orthelowerleg(framebasemetal).Anyundercutshall
berepairedwithanadditionallletorcontouredbygrindingtoremovethemechanicalnotch.Visuallyinspectallweld
stopsandstarts.Weldcratersshouldbelled.Allweldstopsshallbestaggered.Alightcoatofprimerandpaintmay
beappliedafternalinspection.PeriodicInspection:Theseprimaryloadcarryinglletweldsshouldbeinspected
duringroutinemaintenance.
11
WARNING:
HEATFROMWELDINGMAYLOOSENBOLTS.THEREFORE,
ALLTORQUEVALUESSHOULDBERECHECKEDAFTER
INSTALLATIONWHENALLWELDSHAVECOOLED.

MSB Flintec 26 November 2014
Torque values and xing selection
Torquevaluescanvarysignicantlydependinguponthelubricationofthreads.Thefollowingvaluesarebasedonnew,
cleanthreadsin'asreceivedcondition'withoutadditionallubrication.Flintecrecommendstheuseofathreadlubricant,such
asLocktite767orequivalenttopreventtheseizingofthreadsoveralongperiodoftime.Thesetorquevaluescanbeused
forboltswiththislubricantwithoutover-stressingbolts.AllframeboltsaretobeISO/DIN961grade10.9(orSAEGrade8),
alllocknutsGradeC.Usenewxingsatalltimes.Forloadcelltopandendboltswhereloadsarelikelytoreach100%ofits
ratedcapacityandinhighdynamicapplicationssuchasagriculturalaxlesusegrade12.9,(SAEgrade9)usegrade10.9
(SAEgrade8)forallotherapplications.Aminimumof14turnsor28mm(1-1/8")threadengagementisrecommended.
Flexible Mounts -Wheresolidrubberand/orpolyurethaneblocksaretted,ensure28mm(1-1/8")minfor15t
cellsand22(7/8")mmminfor7.5t.ofthreadengagementintoloadcellsandthatanti-rotationdevicessuchastab
washersorNordlockwashersareused.
Application Fastener size Grade Tightening torque
Framemountbrackets
7.5t(16500Lbs)
3/8"16TPIUNF SAE8 37-44FtLbs
M12-1.75(standard) 8.8 90-110
M12-1.75(standard) 10.9 100-120(Recommended)
Framemountbrackets
15t(33000Lbs)
5/8"11TPIUNF SAE8 180-212FtLbs
M16-2(standard) 8.8 200-215Nm
M16-2(standard) 10.9 285-305Nm(Recommended)
DSB77.5t(16500Lbs)
Topandendbots
M16-1.5(ne) 10.9 300-315Nm(Recommended)
M16-1.5(ne) 12.9 350-380Nm(High&dynamicloads)
DSB715t(33000Lbs)
Topandendbolts
M24-2(ne) 10.9 1000-1100Nm(Recommended)
M24-2(ne) 12.9 1200-1300Nm(High&dynamicloads)
12
Socket Head Cap Screw
Fullthreadfromendtobolthead.
Suitablefortheendandtopxings.
Washersnotnormallyneeded.
Allowstheheadtoberecessedintothebracketry.
Hexagon Head Screw
Fullthreadfromendtobolthead.
Usewasehers.
Suitablefortheendandtopxings.
Suitableforframemountxings.
Hexagon Head Bolt
Straightshank-partthreadfromendtobolthead.
Usewasehers.
Strongestxing.
Suitablefortheendandtopxings.
Suitableforframemountxings.
Flat Countersunk Socket Cap Screw
Fullthreadfromendtobolthead.
Suitablefortheendandtopxingswhereloadsarelowto
moderatesuchasaweighplatform.
Washersnotnormallyneeded.
Suitableforframemountxingswherecosmeticsandavailable
spaceistight.
Idealwhereatopplateneedtobeushtting
ThexingsintotheDSB7loadcellaremetriconly:M16-1.5(ne)andM24-2(ne)metricxingstoISO/DIN961are
widelyavailableinvariouslengths,checkwiththeFlintecsalesteamsforavailabilityofstockedxings.
Fixings - TherearemanyapplicationsfortheDSB7onawidevarietyoftrucksandmachines.Mountingstyles,bracket
designandchoiceofxingsaretoonumeroustocovereverypossibilityinthisdocument.Thefollowingxingtypes
givesinstallersachoiceoftechniquesandchoiceofxingsforagivenapplication.Factorssuchasappliedforces,
availablespace,xingavailabilityandcosmeticsallcontributetothechoiceofxing.Threadrolledboltsarethe
preferedchoiceinmostcases.Fixinglengthsdependonthicknessofbracketplatesdeployed.
Example xing styles

MSB Flintec 26 November 2014
Installation mounting techniques - axles and axle beams on agricultural machines
13
l In-line
l Bolted to body
l Top and end spacers
l Welded body stiffeners
BODYRAIL
AXLE
or
BEAM
BODY
l Outboard
l End spacers
l Bolted to body rail
l In-line
l Welded ribs
l Load cell inverted
l In-line
l Top spacer
l Welded ribs
l Outboard
l No spacers
l Bolted to body
l Load cell inverted
l In-line
l No spacers
l Welded to body
l Load cell inverted
l Plug welded upper body brackets
l Outboard
l Welded to body
l Load cell inverted
l Load cell on axle beam
l Plug welded upper body brackets
l Outboard
l Bolted to body
l Load cell inverted
minimumairgap:
7.5t=6mm(1/4")
15t=10mm(3/8")
Don'tallowbolts
toprotrudehere

MSB Flintec 26 November 2014
14
DSB 7 footprint dimensions
DSB7 - 7.5T
(16500 Lbs)
DSB7 - 15T
(33000 Lbs)
mm Inch mm Inch
L1 200 7.87" 310 1.22"
L2 96 3.78" 160 6.30"
L3 29 1.14" 40 1.57"
C1 171.5 6.75" 270 10.63"
C2 67.5 2.65" 110 4.33"
H30 1.18" 40 1.57"
H1 0.5 0.02" 2.5 0.09"
W40 1.57" 54 2.13"
T1 M16X1.5 M16X1.5 M24X2.0 M24X2.0
D17-18 0.67"-0.7" 25-26 1"-1.0.4"
X42 1.67" 56 2.20"
Y20 0.79" 30 1.18"
Y1 36 1.42" 48 1.90"
Y2 42 1.65" 54 2.13"
Z6 0.24" 8 0.32"
Z1 12 0.5" 14 0.55"
Optional spacer-canbeaat
squareifpositionedin-linecarefully.
Y2
X
Y
Y1
ZZ1
D
L3 L3
L2
L1
C1
C2
H
4xT1
Optionalspacer
D
D
Specications DSB7 - 7.5 t DSB7 - 15 t
Rated 0utput (RO) 2.0 mV/V ± 1 % at 7.5t 2.0 mV/V ± 1 % at 15 t
Zero balance ≤ ± 0.2 %*RO (or better)
Combined error ≤ ± 0.15 %
Ultimate overload 300 %
Excitation voltage 5...10 Vdc
Input impedance (RLC) 800 ± 50 Ω
Output impedance (Rout) 700 ± 2 Ω
Insulation resistance (100 V DC) ≥ 5 000 MΩ
Operating temperature range °C–30...+70
Stainless steel 17-4 PH
Fully hermetically sealed IP68 up to 2 m (6-1/2") water depth
Protection according EN 60 529 Cable jacket PVC 4 core unshielded cable (AWG 24)
Cable length 5 m, longer or shorter on request
Connector M12 4-pin
Cable diameter 5.5 mm (0.22")
12-15(0.5-0.6")
10-12(0.4-0.47")
NottoScale
8mm
(0.32")
llet
H1
H1
W
12-15(0.5-0.6")

MSB Flintec 26 November 2014
15
MALEplug
mouldedplugconnector
Moulded 4-pin M12 Connector with 5 meters (16.5 ft) of cable
Pin1 Brown +Excitation 5VoltsDC
Pin2 WHITE +Signal millivoltsfromthejunctionbox&loadcells
Pin3 BLUE -Excitation 0Volts
Pin4 BLACK -Signal millivoltsfromthejunctionbox&loadcells
SIGNAL channel 1 & 2, load cell plug is MALE. Cable plug is MALE
Note,wheretheM12connectorisnotrequired,simplycuttheconnectoroff
anduseanalternativeconnectionmethod.
TheIP65modularM12electricalconnectorsystemisaquickandeasywaytowire-up
onboardweighinginstallations,itsavestimeandcutsdownonmistakes.Together,
witharangeofversatileinputs,combinationsofloadcells,sensorsandtransducers
tosuitthousandsofapplicationsarestraightforward.Powerandsignalconnectors
arekey-wayed,genderedandthumbtightened.
Junction boxes
Junction(splitter)boxesareinternallywiredinparallelforanaloguesystemsand
serialforCANOpensystems.4,6and8wayjunctionboxeshaveFEMALE
signalsockets&MALEindicatorcablesockets.
Extender cables & Junction box to indicator cabeles
Onboardweighingloadcellsandextensometershave5metercable
completewithmoulded4-pinM12MALEcableasstandard.Male-Female
extendercablesforlongerreachapplicationsareavailablein1,2,3,5,7.5
&10metrelengths.A2into1‘Y’cableisavailabewheretwoloadcellare
deployed.
Rewirable 4-pin
M12 Connectors
(alsoknownaseldattachments)
MALE
Wirablewithcablegland
CableInstallation
Flinteccablesarespeciallydesignedtoprovidemaximumsignalstrengthand
highreliability.SubstitutionofcablingotherthanFlintecsuppliedcablingmay
causeinconsistentanderraticreadings.Careshouldbetakenwhenrouting
cabletoprovideprotectionfromsharpedges,drivelinerotation,exhaustpipe,
oranyotherpotentialdamage.Secureinplacewithcabletiestoasnugt.
Assemblyofthecableconnectortothejunctionboxandindicatorshould
notbeforced.Alignthe'keyways'andinsertthecableconnector.Asthe
cableconnectorisbeinginserted,rotatethethreadedsleeveclockwise
untilhandtight.Ensuretheconnectorhasbeenfullyinsertedformaximum
moistureprotectionbywrigglingtheconnectorandretighteningthesleeve.
Cable, connectors and cable installation

MSB Flintec 26 November 2014
Installationchecklist
Mountinganglesorplaceshavebeeninspectedforburrs,inconsistenciesandtrueness
Frameshavebeeninspectedandareingoodcondition
Surfacesforloadcellmountingblocksarerigidandhavebeenreinforced
Checkallbearingbracketwelds(seeweldingprocedurepage10)
Checkallboltsaretorquedtospecications(seepage12)
Checkallconnectorsareproperlyinsertedandtightened
Checkallcablesareroutedandsecuredinprotectedareasoftheframe
Indicatorinstallation:seeIndicatorOperatorsManual
Systemcalibration:seeIndicatorOperatorsManual
RoutineMaintenance
Toensureyouronboardweigheroperatessafelyandaccuratelyfollowthesefourperiodicsteps:-
1. Inspectallweldforsignsofcrackingorcorrosion
2. Retightenallfastenerstospeciedtorquevalues
3. Inspectcableandconnectorsfordamage,tightnessandcleanliness
4. Cleantruck/trailersuziconnectors
16
Flintec Group AB
W4/5 Capital Point, Capital Business Park
Wentloog Avenue, Cardiff, CF3 2PW - UK
Tel [phone]
Fax [phone]
www.intec.com