LOAD CELL INSTALLATION GUIDELINES V1.

0_03082010:Layout 1 19/08/2010 09:57 Page 1

Load Cell
Installation Guidelines

Vishay PM Onboard Ltd

Airedale House
Canal Road
Bradford
BD2 1AG
T: 01274 771177
F: 01274 781178
www.vishaypg.com/onboard-weighing

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Load Cell Installation Guidelines

IMPORTANT INSTALLATION INFORMATION AND LIABILITY WAIVER

Document Information
Vishay PM Onboard Ltd. design and manufacture on-board vehicle weighing
equipment. These installation guidelines are provided solely for the use of trained
The reference number for this document is:
fitters and represent the correct, safe and recommended method of installation.
They must be followed fully to ensure proper, safe installation. Failure to do so
may result in serious consequences including, but not limited to, failure of the lcig/v1.0/03082010
system to function properly and damage to the weighing equipment that could
jeopardise the stability and safety of the vehicle.
This reference filename is divided into 4 areas, these are:
Vishay PM Onboard Ltd. accepts no responsibility or liability for
consequences arising from any improper installation of the weighing lcig This designation refers to the type of equipment
equipment including but not limited to, any misapplication or supplied, by Vishay PM Onboard Ltd. in this
misinterpretation of the installation information contained herein.
case load cell installation guidelines.
Strict observance of these guidelines should help to ensure accurate weight
measurement and enable safe operation of the vehicle. Failure of our on-board v1.0 This denotes that this documentation is version 1.0.
vehicle weighing equipment due to poor installation workmanship or incorrectly
installed elements remains solely the responsibility of the installer.
03082010 This is the date on which the document was
Vishay PM Onboard Ltd. do not accept responsibility for the structural integrity of compiled.
the vehicle concerned, for any part thereof, and for its proper, safe operation. In this case the date was 3rd August 2010.
The company also reserves the right to make any amendments and alterations to
this document deemed necessary. You should ensure you have the current version
of this information by contacting Vishay PM Onboard Ltd. prior to performing
installation, such as on our website at vishaypg.com/onboard-weighing.

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Bracket Details Contents

Shown are the details of the main brackets used with this type of installation. These
designs should be used as a basis for fabrication of suitable brackets for use on each Overview.................................................................................. 2
individual assembly. Details available on request. Equipment Assembly Principles............................................... 3
Deep Weightlift Front cradle Installation Types..................................................................... 3
No 192530 Front cradle bracket. For installing a load cell under the front tipping ram of a
Weightlifter trailer and other trailers where dimensions are similar. Suits: Weightlifter trailer, Cell Mounting Types................................................................ 5
Craven Tasker, Montracom, Stas.
Other Cell Mounting Considerations........................................ 7
117 Craven Tasker/Weightlifter/Wilcox Front Cradle
No 194530 Front cradle bracket. For installing a load cell under the front tipping ram of a Chassis & Superstructure Preparation.................................... 10
Wilcox trailer and other trailers where dimensions are similar. Suits: Wilcox Craven Tasker
Stas Weightlifter Rothdean. Bolting Requirements............................................................... 15

119 Wilcox Front cradle Final Load Cell Assembly......................................................... 18

No 194640 Front cradle bracket. For installing a load cell under the front tipping ram of a
Load Cell Slot Clearance Check.............................................. 20
shallow Wilcox trailer and other trailers where dimensions are similar. Suits: Wilcox.
Welding Procedures................................................................. 21
Crane Front cradle
No 196830Crane Fruehauf with special weldblocks. Specifically designed for the Crane Cables...................................................................................... 24
Fruehauf/General Trailers trailer, this cradle brackets fit interchangeably under the front
tipping ram and is secured with six M16 grade tensile fixings. Suits: Crane Fruehauf, Junction Boxes......................................................................... 24
General Trailers, Don Bur.
Routine Maintenance............................................................... 25
Neville Charrold 'Z' Mount Front
No 198020 Front, under ram bracket. For Neville Charrold trailers only. Installation Checklist................................................................ 25

Rear Weightlifter 70mm No 192580 Connection Cover.................................................................... 26

70mm Weightlifter spiral grooved bore. For mounting directly on a hinge bar, this bracket
is used with a top body bracket No 192575 Abbreviations........................................................................... 26

Rear Wilcox 2.5" No 198180 Contact Details......................................................................... 26

Rear Montracon 70mm No 19388070mm Load Cell Details...................................................................... 27

Craven/Tasker/Montracom. For mounting directly onto a hinge bar, this bracket is used Bracket Details......................................................................... 28
with top body bracket No 193872

Montracon No 196830 Montracon rear top body bracket.

Top body rail bracket for rear hinge mounts

Weightlifter New build Suits 70mm bar No 192575

Suits 70mm new bar Weightlifter new build. Top body rail bracket for hinge mounts.

Wilcox No 198192 Top body rail bracket for rear hinge mounts.

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Overview Load Cell Details

The PM Onboard frame and body weighing system utilises highly advanced electronic Shown are the details of the main load cells used with this type of installation.
measuring equipment.
PM30945 - 10 tonne capacity. Millivolt output. Ununitised.
Weight is ‘sensed’ by load cells that are mounted between the body and the truck and Part No. 234512. Maximum spacing 18 feet (5.5 metres)
trailer frame.
PM30945 - 10 tonne capacity. Millivolt output. Unitised.
These installation guidelines are aimed at the person or organisation who is installing PM Part No. 234522
Onboard load cells, junction box and associated wiring and modifying the vehicle to suit
this equipment. PM30870 - 12.5 tonne capacity. Millivolt output. Ununitised.
Part No. 237012
This guide does NOT cover the installation and calibration of the display, camera or
printer equipment associated with the load cell equipment. PM30870 - 12.5 tonne capacity. Millivolt output. Unitised.
Part No. 237022
PM Onboard load cells are available for most types of trucks and trailers. Due to
differences from model to model there may be some significant assembly variations. The
PM30945 CAN - 10 tonne capacity. Digital CAN output. Ununitised.
installation process is virtually the same whether it is being performed as a retrofit, or to a
Part No. 234513
new vehicle.
PM30945 CAN - 10 tonne capacity. Digital CAN output. Unitised.
In this guide reference is made to welding on items and bolting on items, before attempting
Part No. 234523
to weld or bolt items to a specific vehicle the guidance of the vehicle manufacturers
MUST be sought because some vehicle chassis are made from heat treated steel.
PM30870 CAN - 12.5 tonne capacity. Digital CAN output. Ununitised.
Part No. 237013
It is extremely important to follow these installation guidelines and use the specified
materials to ensure that the completed assembly will maintain it’s high strength for
PM30870 CAN - 12.5 tonne capacity. Digital CAN output. Unitised.
maximum safety. This will also result in minimum installation costs, high accuracy and long
Part No. 237023
life for your on vehicle weighing system.

WARNINGS

Failure to follow these instructions could cause a hazardous operating condition.

Always ask if in doubt.

Installation must be in accordance with all national laws and regulations.

Installation must be carried out in a safe and secure manner.

Upon completion of the load cell installation, you will need to install the PM Onboard
Digital Weight Indicator and calibrate the load cell system (calibration is simply an
electronic adjustment of the load cell to compensate for installation variations). Complete
instructions for these procedures can be found in the relevant manual included with your
PM Onboard Digital Weight Indicator.

NOTE
Please refer installation questions to PM Onboard Technical Helpdesk. See back
cover for telephone and fax numbers.

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Connector Cover Equipment Assembly Principles

PM Onboard recommends that a cover is provided to protect outboard facing load cell PM Onboard body to chassis weighing load cells are ideal for industrial weighing
glands from road damage such as flying stones etc. applications and suitable for measuring either gross vehicle weight or the weight of cargo
being loaded or delivered. The basic weighing system consists of load-supporting load
This cover can be designed and fitted at the time of fitting the load cells. cells, a digital weight indicator (DWI) capable of being calibrated to display the weight in
convenient units kg and electrical cabling connecting the load cells and indicator
This cover should be bolted on to enable easy accessibility for the gland and cable
underneath. Optimum weighing performance is obtained when the load cells are installed between the
load-carrying superstructure (box, tank, flatbed, etc.) and the vehicle chassis and carrying
Abbreviations 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
The following are definitions of abbreviations used within the text of this manual: chassis, as this will result in an alternate load path that will degrade the accuracy of the
scale system.
ASTM American Society of Testing and Materials
AWS American Welding Society Typical applications include: tippers, tankers, flat-bed, refuse and van-type superstructures
DOT U.S. Department of Transportation mounted on either truck chassis or trailers.
FCAW Flux Cored Arc Weld
GMAW Gas Metal Arc Weld
SAE Society of Automotive Engineers
SMAW Shielded Metal Arc Weld

Contact Details
Installation Types
Vishay PM Onboard Ltd
Airedale House
Rigid Truck Installations
Canal Road
support the superstructure and payload
Bradford
with load cells mounted directly to the
BD2 1AG
truck frame.
T: 01274 771177
F: 01274 781178

load cells

Trailer Installations
are usually accomplished by separating
the rear suspension subframe from the
trailer frame and installing load cells
between these two structures

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Tipper Installations Routine Maintenance

Support the superstructure and payload
Listed below are four simple steps that should be periodically performed to ensure safety,
with load cells mounted directly to the
and to maintain your weighing system in top operating condition.
truck frame, on the hinge bar and below
the tipping ram.
1. Inspect all welds for signs of cracking or corrosion.

2. Re-tighten all fasteners to specified torque values

3. Inspect cables and connectors for damage, tightness and cleanliness.

4. Clean truck/trailer connections.

Semi-Trailer Installations
Installation Checklist
Support the superstructure and payload
with load cells mounted directly to the o Mounting angles or plates have been inspected for burrs, consistencies, and trueness.
truck frame, on the hinge bar and below
the tipping ram. o Frames have been inspected and are in good condition.
Occasionally weld blocks can be welded
o Surfaces for load cell bearing plates are rigid and have been reinforced.
directly onto the chassis and hinge bar
mounted via a trunnion.
o All bearing plate welds “triple pass”

o All bolts are torqued to specifications

o All connectors are properly inserted and tightened

o All cables are routed and secured in protected areas of the frame.
Refuse Truck Installations
o Indicator Installation, Camera Installation, System Calibration: see the appropriate
Support the superstructure and payload manual for these.
with load cells mounted directly to the
truck frame under the plate and at the o Bolt clearance check
rear of the body where the load is tipped
into. o mV, weight, PI factor check - please see appropriate manual

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Cables Cell Mounting Types

PM Onboard cables are specially designed to provide maximum signal strength and high
reliability. Substitution of cabling other than PM Onboard supplied cabling may cause
inconsistent and erratic readings. Care should be taken when routing cable to provide
protection for sharp edges, driveline rotation, exhaust pipe, or any other potential damage. Tipping Vehicles
Secure in place with cable ties to a snug fit.
Two basic mounting styles are used for
installing weighing systems:
chassis
1 - Front tipping ram mounts
2 - Rear hinge bar mounts

cell wiring The front end load cell is simply

mounted between the tipping ram and
the chassis via a trunnion and cradle
bracket.
load cells
air lines
cable ties
Junction Boxes

The four input junction box should be located mid-chassis at a suitably accessible
location and fixed into position by the use of two M6 x 60mm long screws and nuts.

NOTE

The holes for these bolts should be drilled no more than 1mm larger than the bolts. Existing The rear hinge bar mount is simply
holes intended for other purposes should not be used. installed between the body and the
hinge bar, using brackets above and
The screw-on connectors are moulded-sealed-for-life and designed to provide moisture below the load cell. load cells
free operation. The connections are clearly marked; female at the junction box for the load
cell input and male for the junction box to indicator cable.

indica
to fron tor lea
t of ve d
hicle

NOTE:
MOUNTING OF JUNCTION BOX MUST BE ON THE
INSIDE OF R/H CHASSIS RAIL IN ORIENTATION
SHOWN FOR INCLINOMETER TO WORK CORRECTLY.

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Rigid Vehicles Final Inspection

Long service life depends on quality application of the fillet welds and THE FINAL SIZE OF
Two basic mounting styles are used for superstructure THE FILLET. There shall be no undercut on either the upper leg (on the bearing plate) or
installing frame mounted on-board cells the lower leg (frame base metal). Any undercut shall be repaired with an additional fillet or
on these types of vehicles: contoured by grinding to remove the mechanical notch. Visually inspect all weld stops and
starts. Weld craters should be filled. All weld stops shall be staggered. A light coat of primer
1 - in-line mount and paint may be applied after final inspection.
2 - outboard mount

An in-line mounted load cell is simply mounting

installed between the flanges of the angle
upper and lower frame members and
load cell
aligned with those frame members. 1. Root Pass
chassis
2. Base Pass

3. Final Pass
Ž

4. Undercut Œ  

An outboard mounted load cell is

installed alongside the frame members
using brackets located outboard of the
frame members.
superstructure
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. Ensure free movement with no straining or trapping during
movement of bodies, trailers etc.

mounting bracket
Periodic Inspection
load cell
These primary load carrying fillet welds should be inspected during routine maintenance.
chassis

WARNING
Heat from welding may loosen bolts. Therefore, all torque values should be
rechecked after installation when all welds have cooled.

DETAILS OF BRACKET CONSTRUCTION FOR EACH STYLE AND

LOAD CELL TYPE ARE INCLUDED AT THE END OF THIS GUIDE.

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Electrode Specifications Other Cell Mounting Considerations

The electrode shall be as detailed in the table below or equivalents.. 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
GMAW/MIG illustrates the features of each mounting style:
Process using a gas-shielded wire electrode.
Spray transfer method only. E70-S wire electrode. Use on up to 7mm thick steel. In-Line Mounting Outboard Mounting
Only for use in flat position.
Used when outboard clearances or suspension Requires space for load cell installation
are limited. outboard of chassis.
SMAW/STICK
Process using a flux coated rod electrode. Requires an upper and lower mounting
Requires only one mounting bracket per load cell.
Type E7018 electrodes. MUST be kept dry. Do not require pre-heat. All position bracket per load cell.
electrode. Will raise the overall vehicle height approximately Will raise the overall vehicle height
3.5” (90mm) unless frame is recessed. approximately 1” (25mm).
FCAW/MIG VARIANT
Process using a flux cored wire electrode, can be gas shielded or not depending Mounting holes for the load cell must be added to Mounting holes for the load cell are
the frame structure. located in the mounting brackets.
on electrode wire used. Type E71T-5 or E70T-5 electrode.
Allows for either inboard or outboard facing cable Outboard facing cable connector is usually
Preheat connector. required.

The welding blocks and the base metal mounting surface can be warmed if required in
preparation for welding to reduce shrinkage stress. Any suitable torch arrangement is Gland Orientation
satisfactory. Spot heating shall be avoided. The preheat temperature shall be a MINIMUM
of 70°F (20°C) and a MAXIMUM of 150°F (65°C). The load cell can be orientated so that the cable gland is located on either the outboard
or inboard side of the load cell. Outboard located glands generally are more accessible for
Cleaning Before Welding installation and service, but need a cover plate for protection from road damage. Inboard
facing glands provide improved protection for the gland.
The welding block will be sent ready for welding. The base and edges of the bearing plate
shall be visually inspected to verify that there is no oil, grease, dirt, paint or other foreign Outboard mounted load cells generally have limited access for inboard facing glands. For
substance that will reduce the weld quality. The mounting angles shall be surface ground this reason, inboard facing glands are usually used only with in-line mounted load cells.
or power wire brushed so as to remove all paint, primer, or other surface coating. An area
the size of the bearing plate plus 25mm shall be cleaned and ground to bare base metal.

In Process Cleaning

Each fillet 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.

outboard inboard facing

facing cable cable gland
gland

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Load Cell Installation Guidelines Load Cell Installation Guidelines

The most common position for load cell mounting is to position the load cell so that the Welding Procedures
bearing plates are underneath the load cell. However, installation can sometimes be
simplified by inverting the load cell and installing with the bearing plates above the load Bearing Plate Welding
cell, especially when combined with the outboard mounting style. This method can be
used with either the rigid type or the lifting type. Please read the welding procedures completely before proceeding. The welding of
the bearing plates is the most crucial step in the installation process.

Rigid Type Take precautions to ensure that the vehicle electrical system is not damaged by the
welding.

TO PREVENT ELECTRICAL CURRENT FLOW 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.

1. Tack weld the bearing plates to the mounting angles or brackets.

inverted
load cell 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.

Tipping Type
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, FCAW or standard MIG welding
technology.
The user should NOT use GMAW short circuit transfer.

bearing plates Weld Configuration

The bearing plate shall be attached using a multipass fillet weld sequence as shown in the
illustration below. The weld is to be 13mm (1/2”) finished size.

load cell 13mm

1. Root Pass
2. Base Pass
3. Final Pass
4. Load Cell
5. Bearing Plate

13mm

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Load Cell Slot Clearance Check Cantilevered Loading of Load Cells

After every other operation is complete it is necessary to check the clearance in the load Locate load cells within 3 feet (1m) of the ends of the superstructure, if possible, to avoid
cell slots. This check is necessary to ensure that the top mounting bolts do not protrude overhanging loads. This not only provides for a stronger structure but can avoid potential
which can affect the performance of, or result in damage to the load cells. accuracy problems.

As the images show the clearance can easily be checked by inserting a flat blade
screwdriver with a shaft diameter of 3mm into the rubber in the lower edge of the slot
directly below the bolt. If the screwdriver passes through then the bolt length is correct. If
the screwdriver does not pass through then either the length of the bolt or the thickness of
the mounting bracket needs to be adjusted accordingly.
Mounting Blocks
It is VERY IMPORTANT that Load Cell mounting blocks are assembled with the angled
ends facing each other, as shown below and not the other way round.

The load cells are factory zeroed in this position and MUST be assembled and welded on
the vehicle in the correct position to ensure weight accuracy repeatability when in use.

ü Ñ
Load cell CORRECT mounting Load cell INCORRECT mounting

Correct Wrong

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Chassis & Superstructure Preparation
When preparing for load cell attachment an important distinction must be made between
chassis and superstructure.
Chassis
A chassis is a main load carrying assembly on a vehicle, carrying the engine, wheels and
body etc. These are generally made from heat treated steel and if so, should NOT be
welded. Any brackets fastened to these should be bolted in position.
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 set 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 1/16” (1.5mm)].

Superstructure
A superstructure is a sub-chassis used to carry the body and load etc and is generally
fastened to the body via brackets or mountings. These are generally of non-heat treated
steel and can be welded or bolted as required. superstructure

Trailers are generally regarded as superstructure type frames.

IT IS IMPORTANT that the manufacture of the vehicle is consulted BEFORE any work
of this type is carried out to a vehicle.

PM Onboard provide advice and drawings on the materials, processes and types of
brackets etc., required to add load cells.
lower bracket
One very important factor is the clearance required between the body/superstructure and
the chassis after load cells are added. This is because the body/superstructure carries all load cell
the load, the weight of which is measured by the load cells and if the body/superstructure
touches the chassis at any point the loadpath through the cells will be short circuited and
the correct weight will not be indicated. chassis
weld load cell bearing
Superstructure Preparation plates in place to
lower angle bracket
Load cell mounting brackets are generally attached to the superstructure by means of
welding. In order to provide for the mounting of load cells and mounting brackets some
modification to the superstructure may be required.

The modifications may be as simple as providing a flat surface for bracket welding or may
be as extensive as providing a recess in the underframe for the mounting of the load cells.

Modification to the superstructure will vary according to the specific 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
underframe of the superstructure for the load cell mounting bolts.

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Load Cell Installation Guidelines
Final Load Cell Assembly
Assemble upper mounting brackets to the load cells using the bolt kits 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 bolts are the proper length and do not bottom out.
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.
top mounting bolts
upper mounting bracket
load cell
mounting bolts
load cell
The load cell/upper mounting bracket assemblies are now ready to be installed on the
superstructure. To do this, place temporary spacers (usually 1” or 25mm if using metric
plate) 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.
Place the load cell assemblies on the vehicle frame mounting brackets.
Adjust the load cell assemblies into their final position, verifying fit 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).
Lift the superstructure and remove the temporary spacers.
18 lcig/v1.0/03082010
Load Cell Installation Guidelines
Whenever making modifications to a structure, care must be employed to provide for bolt
strength and rigidity (stiffness) for the finished installation. Every structure will deform
(bend, twist or sag) to a certain degree when carrying a load. The installer must ensure
that the modified 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’ 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.
Superstructure Recess Mounting
Often the most practical method for installing on-board frame mounted cells (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 underframe. A general recommendation
for this approach is shown in the following illustration. The installer should assure that any
modified structure will retain the strength and stiffness properties of the original structure.
web stiffeners re-inforcing plate
flange
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Load Cell Installation Guidelines Load Cell Installation Guidelines

Alignment Choosing the Correct Bolt

From the diagram below the correct bolt length and part number can be determined to suit
Because the installation of weighing equipment involves the eventual separation of the the material thickness of the mounting bracket used.
body superstructure from the supporting chassis, care must be taken to ensure the
separated elements are reinstalled in the proper alignment. Marking the relative positions Top Bracket Material Thickness (X) Bolt Length (Y) Part No.
on the frame elements before separation is an effective means of assuring proper 4mm 1.25” (31.75mm) 331390
realignment. Also ensure the straightness of frame elements when cutting or welding to 10mm 1.5” (38.1mm) 331342
prevent undesirable bending or warping during modification. The use of a simple stiffener 12mm 1.625” (41.275mm) 331341
(stiff-back), welded into place prior to modification, is effective for this purpose. 15mm 1.75” (44.45mm) 331043
22mm 2.0” (50.8mm) 331044
29mm 2.25” (57.15mm) 331046
35mm 2.5” (63.5mm) 331338
48mm 3.0” (76.2mm) 331020
Mounting Structure
60mm 3.5” (88.9mm) 331021
Optimum performance of the scales is dependent upon a solid mounting base for the load
4mm Thick Washer Part No. 331339
cells. Brackets of heavy construction [usually 1/2” (12mm) thick steel] are required. Since
this is a thicker section than usually found on trucks and trailers, a cover plate may be
top bolt
necessary to evenly distribute forces to avoid stress concentrations and possible cracking top bracket
material washer
in the thinner sections of the superstructure. Locating load cells in the immediate vicinity

4
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

X
on-board weighing system.

Y
24
load cell

welding block

superstructure

6mm thick rubber pad

cover plate

Example:
The load cell thread engagement depth and washer thickness are constant at 24mm and
4mm respectively. If the desired bracket material thickness is 15mm then the bolt length
would be calculated as follows:
mounting bracket
Material Thickness (X) + Washer + Load Cell Thread Engagement Depth = Ideal Bolt Length (Y)
15mm + 4mm + 24mm = 43mm
It is acceptable to have up to 2mm of the bolt extend further than the 24mm of thread
engagement in the load cell, so the correct bolt from the table would be a 331043 which is
44.45mm.

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Torque values can vary significantly depending upon the lubrication of threads. The
following values are based on new, clean threads in “as received condition” without
additional lubrication. PM Onboard 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.
When separating the superstructure from the supporting frame, be careful when rerouting
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 sufficient length to allow for frame separation
or are not properly protected at installation.

All bolts are to be minimum grade 8.8, all lock nuts Grade C. Use only new bolts and lock Upon completion of the load cell installation, look closely at all the elements of the
nuts. mechanical installation to avoid problems with pinched wires, ruptured hoses, etc.,
especially during the first operation of any moving structure of the tipper body.
Application Fastener Size Application
Frame Mount 5/8” - 18 UNF 225-250 ft-lb (300-340 Nm)
M16 225-250 ft-lb (300-340 Nm)
Load Cell Mount 1 1/4” - 12 UNF Min 1,000 ft-lb (1,360 Nm)
1” - 14 UNS 760-840 ft-lb (1,030-1,140 Nm)

Top Load Cell 7/8” - 14 UNS 570-630 ft-lb (775-850 Nm)

Mount 1” - 14 UNS 760-840 ft-lb (1,030-1,140 Nm)

CAUTION

Frame angles and plates may vary between chassis and body. Ensure that top load
cell mount bolts do not ‘bottom-out’ in the load cell as inaccuracies will result.
Several bolt lengths are available however, the 1.1/2” (38mm) should suffice.

top load cell

mounting bolt

load cell mounting bolts

2 per cell

bottom load cell

mounting bolts

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Load Cell Installation Guidelines Load Cell Installation Guidelines

Chassis Preparation Bolting Requirements

Reminder The structural requirements for the load cell mounting brackets are affected by the actual
Load cell mounting bracket installation methods differ depending upon whether the weight being supported by the load cells and by dynamic service factors caused by road
supporting structure is a truck chassis or a trailer suspension subframe. Truck frames are conditions. Bolted load-carrying brackets are susceptible to slippage if the proper number
manufactured from heat treated high strength steel, requiring load cell mounting angles or of bolts are not used or if the bolts are not tightened to the recommended torque. Generally
brackets to be bolted to these frames. Trailer subframes however, are not heat treated and a MINIMUM of 6 bolts per bracket would be used on a normal installation.
mounting brackets can be welded to these frames.
Bolts per Bracket Maximum Load on Load Cells
CAUTION
Front Rear Highway Use Only Rough Road Use
Review truck or trailer manufacturer’s recommendations before welding to frame. 6 5 27,500 lb (12,500 kg) 7,000 lb (3,175 kg)
6 6 Not Required 9,000 lb (4,082 kg)
6 7 Not Required 10,000 lb (4,536 kg)
Frame Rail Inspection 6 8 Not Required 12,000 lb (5,443 kg)
Inspect the frame rails to ensure they are clean, straight and free of cracks, corrosion, 6 9 Not Required 12,500 lb (5,670 kg)
pitting, burrs or any other imperfections that may affect the installation and fit of the
mounting angles/brackets, or the strength of the frame.
NOTE:
Bolt holes in mounting structures must be drilled, not burned. Holes should not be
Existing Pipes or Wires oversized more than 1/32” (1mm) to ensure a snug fit for bolts.
Before cutting or welding to attach or remove any items ensure that any pipes or wires near
to these items are re-routed well away and clipped to the chassis or body. Use a minimum of 5 bolts per mounting angle or bracket. Also locate bolts within 1”
to 1 1/2” (25mm to 38mm) of each end of the mounting angle/bracket. Do the same
for the edge of each cut out deeper than 1” (25mm).

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 1” (25mm)
radius and no sharp corners. Remove angles/brackets, trim as required, and grind edges
smooth.
Attach the mounting angle/bracket using SAE Grade 8 quality bolts, Grade C lock nuts
(ISO/DIN Grade 10.9) and a hardened washer under each lock nut. The bolts must have
a diameter of 5/8” (16mm) minimum, and sufficient 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.

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

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.

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