Miller Electric Shopmaster 300 AC/DC Installation guide

Miller Electric Shopmaster 300 AC/DC Installation guide
Self-Weighing Truck and Trailer Scales
Air-Weigh Scales
Welded Steer Axle Deflection
Sensor Kit Installation Guide
For Use on Vehicles with Steel Spring Steer Axles
Please Read Before Installing
901-0146-001 R0
Table of Contents
ABOUT STEER AXLE DEFLECTION SENSORS ........................... 3
TOOLS REQUIRED ....................................................................... 4
Optional Tools .................................................................. 4
Preparing the Steer Axle Sensor Brackets ........................... 5
Welding the Bracket ............................................................ 7
Adding a Protective Spray Paint Coating ............................. 8
Installing the Deflection Sensor ........................................... 9
Setting the A/D Values ...................................................... 11
A/D Reading is BELOW 750 ........................................... 12
A/D Reading is ABOVE 1250.......................................... 12
Final Sensor Torque ....................................................... 13
Steer Axle Finishing Touches ............................................ 13
LIMITED WARRANTY ................................................................. 18
PROCEDURE FOR WARRANTY CLAIMS ................................... 19
About Steer Axle Deflection Sensors
The Air-Weigh steer axle deflection sensor is a major component
of several tractor and truck scale kits. Once installed, it allows the
user to determine the weight resting on a spring-ride steer axle.
This installation guide provides instructions for welding the steer
axle brackets and installing the deflection sensor. See the User
Guide included with your kit for complete scale installation,
calibration and operation instructions.
Follow the installation procedures in this guide exactly for the most
accurate weighing. This guide assumes that you have already
installed the QuickLoad or LoadMaxx display and, if you are using
a LoadMaxx scale, the Comlink, or that you have access to a
deflection sensor test box. You will need to connect the deflection
sensor to either the display or the test box in order to adjust the
sensor correctly.
Please see the User Guide, included with your scale kit, to
calibrate your scale after installation.
Tools Required
You will need to supply to following tools to install deflection
sensors on the steer and drive axles.
40-grit medium sandpaper
Chalk or permanent marker
MIG or ARC welder
For ARC welder: E7018 welding electrodes OR
For MIG welder: E70S-3 or E71T-1 welding wire
At least two C clamps
Flat-blade screwdriver
9/16-inch combination wrench
Torque wrench, 20 – 80 ft-lb
9/16-inch socket and 3/8-inch socket handle
Enamel spray paint, any color
Tape measure
Optional Tools
Deflection sensor test box, p/n 1001
Installing the Steer Axle Sensor
Preparing the Steer Axle Sensor Brackets
1. Locate and mark the center of the steer axle (Fig. 1)
Center Mark
Fig. 1: Marking the Center of the Steer Axle
2. Using chalk or a permanent marker, mark the top of the steer
axle 3" on either side of the center mark (6" in total). Clean
this area. If the axle is heavily caked with dirt or grease, use
Brakleen to remove the worst. Then clean the 6" area using
two of the alcohol pads supplied in the installation kit. See
Fig. 2.
3. Using 40-grit medium sandpaper or a pneumatic grinder,
sand the 6" area until nothing remains but bare metal. We
recommend that you partially sand down the mold line as
well. See Fig. 2.
Alcohol Pad
Fig. 2: Cleaning and Sanding the Steer Axle
4. Re-clean the sanded area on the steer axle using one of the
supplied alcohol pads.
5. Re-mark the center of the steer axle (Fig. 1)
6. Verify that the bracket contact pads fit into the sanded area
and that no axle paint is left under the pad. If there is any
paint at all that will be touching the brackets, sand until it has
been removed.
7. Once you have prepared the axle, place the new bracket
onto the axle to ensure that it fits properly. All four bracket
mounting pads should sit firmly on the axle without rocking in
any direction. If the bracket rocks, sand or grind off any
excess axle material until the bracket fits properly.
Welding the Bracket
Air-Weigh takes no responsibility for damage or failure of
the steer axle due to improper welding
1. Place the new bracket assembly at the center of the axle
(Fig. 3). Use C clamps to hold the bracket in place. Make
sure you leave the alignment tool in the bracket assembly
while welding.
Fig. 3: Bracket assembly centered on axle
2. Fillet weld a full bead on the front and back edges of each
bracket piece, as per ANSI/AWS 2.4-79, AWS A5.4, AWS
A5.9 and AWS A5.22 standards (Fig. 4). Do NOT weld the
sides of the bracket, only the edges indicated below. AirWeigh recommends that you use equipment similar to Miller
Shopmaster 300 AC/DC; AMP/VOLT setting of 22; wire
speed of 3.5; and a welding argon gas mixture of 75/25. MIG
welding should use Lincoln L-56 or Lincoln Arc L-56. MIG
welding will use the same settings as the Miller Shopmaster
noted above.
NOTE: Do not operate the vehicle while the alignment tool is
still in place.
Fig. 4: Welded axle and bracket
Adding a Protective Spray Paint Coating
To prevent steer axle corrosion, we recommend you spray paint
around the base of the bracket.
1. Using any enamel-based spray paint, paint around the base
of the bracket and over the welded section. Paint all bare
metal around the bracket completely.
2. Once the paint is dry, we recommend that you paint all
exposed metal a second time.
Fig. 5: Spray Paint Coating
Installing and Adjusting the Steer
Axle Sensor
Installing the Deflection Sensor
1. Remove the alignment tool from the brackets. It should fit
loosely. Retain the two 3/8" bolts and 3/8" nuts to use when
you install the deflection sensor.
2. Clean the bracket channels with an alcohol pad.
3. Clean the sensor ends with the remaining alcohol pad.
4. Insert the steer axle sensor with its cable extending toward
the side of the vehicle where the sensor extension cable has
been routed to the firewall. Make sure the word “TOP” faces
up (Fig. 6).
Fig. 6: Inserting the Sensor into the Bracket
5. Align the steer axle sensor with the holes in the steer
axle bracket assembly.
6. Insert one bolt through the bracket hole on the sensor end
with the word “TOP” on it (Fig. 7). Place a washer and a nut
at the end of the bolt and hand-tighten the nut.
7. Insert the second bolt through the second bracket hole.
Place the connector assembly bracket tab on the other side
of the bolt facing away from the bracket. Then place a
washer and a nut behind the tab. Hand-tighten the nut
(Fig. 8).
Fig. 7: Attaching the Sensor to the Bracket
Fig. 8: Installing the Connector Tab
Setting the A/D Values
NOTE: A/D refers to the analog-to-digital conversion of the
sensor reading.
1. To assemble the connectors, insert the deflection sensor
connector plug into the sensor extension cable connector OR
connect to the deflection sensor test box, not included in your
installation kit. Ensure the locking tabs on the connector plug
engage completely (Fig. 9).
2. Tighten both nuts and use a torque wrench to torque to 30 ftlbs.
3. Verify the A/D reading using the display in the cab (start the
ignition to power on the display) or the deflection sensor test
box. If the reading is within range (750 to 1250), continue to
instructions for the final sensor torque. If the reading is not
within range, follow the instructions below.
Fig. 9: Assembling the Electrical Connector
NOTE: When tightening the bolts, ALWAYS torque the
nut, NOT the bolt head.
A/D Reading is BELOW 750
If the A/D reading is below 750 or there is no A/D reading at all,
follow the steps below.
Loosen the nut on the non-cable end of the sensor.
Exert upward pressure lightly with your fingers (or a
screwdriver, if necessary) under the non-cable end of
the sensor until the A/D reading is between 750 and
Tighten the nut on the non-cable end of sensor and
torque to 30 ft-lbs. If the A/D readings are still within
proper range, continue to instructions for the final sensor
A/D Reading is ABOVE 1250
If the A/D reading is above 1250, follow the steps below.
Loosen the nut on the non-cable end of the sensor.
Exert downward pressure lightly with your fingers on the
non-cable end of the sensor until the A/D reading is
between 750 and 1250.
Tighten nut and torque to 30 ft-lbs. If the A/D reading is
still in range, proceed to instructions for the final sensor
Final Sensor Torque
1. Tighten both bolts to 60 ft-lbs.
2. Perform a final check of A/D values. If not within range,
repeat the steps for altering A/D readings.
3. If you are using the deflection sensor test box to set
A/D values, disconnect the box and connect the
deflection sensor cable to the sensor extension cable.
Steer Axle Finishing Touches
1. Slide the connector assembly onto the connector
bracket tab mounted on the deflection sensor bracket, by
inserting the tab into the grooves on the bottom side of the
bracket. Ensure the connector assembly slides completely
on the mounting tab.
2. Route the cable coming out of the receptacle portion of the
connector assembly so it can be used for a driver’s side
hookup or a passenger side hookup.
3. Driver’s side sensor orientation: Facing toward the rear of
the vehicle, route the cable from the connector assembly so
it runs to the right of the steer axle sensor assembly (Fig.
Fig. 10: Driver’s side orientation
NOTE: Make sure there is enough slack in the sensor
extension cable between the axle and the frame to allow for
axle movement.
4. Passenger’s side sensor orientation: Facing toward the
rear of the vehicle, route the cable from the connector
assembly so it runs to the left of the steer axle sensor
assembly (Fig. 11).
Fig. 11: Passenger’s side orientation
5. Mount the cover over the sensor and the sensor brackets so
that the sensor cable is completely under the cover. The
bracket band clamps should emerge from the cover’s side
ports (Fig. 12).The sensor extension cable should emerge
from the cover’s end port on whichever side you choose to
route the cable.
Fig. 12: Placing the Cover
6. Very loosely install band clamps around the steer axle on
both ends of the deflection sensor cover. Ensure that the
band clamp on each side circles both the steer axle and the
cover flange (Fig. 13). Fig. 14 shows completed installation.
Fig. 13: Attaching Band Clamps to Cover
7. Secure the sensor cable to the axle. Run the drive sensor
extension cable along the rear of the axle toward the side of
the truck (driver’s side or passenger’s side), securing with a
band clamp. Place split loom over the band clamp where it
crosses over the cable. Secure the cable to the band clamp
with nylon ties. See Fig. 15. Use additional 24” nylon ties as
required to secure the cable to the steer axle.
Fig. 14: Cover with Sensor Extension Cable
Band Clamp
Split Loom
Sensor Extension
Nylon Tie
Fig. 15: Securing the Sensor Extension Cable to the Axle
Limited Warranty
For product failures due to material or manufacturing defects, Air-Weigh will
replace or repair all components for up to 3 years from shipment date to the
end-user Air-Weigh customer. These three-year components include: Displays,
ComLinks, Sensors, Power Cables, Sensor Assemblies, Sensor Harnesses,
and all other associated external components. Air-Weigh assumes no
responsibility for administering warranty claims directly with any third party end
The responsibility of Air-Weigh under this warranty is limited to the repair,
replacement, or credit of the defective part or assembly.
This warranty does not cover incidental or consequential damage to persons or
property caused by use, abuse, misuse, or failure to comply with installation or
operating instructions. This limited warranty does not apply to any product that
has failed due to accident, abuse, alteration, installation not consistent with
printed installation instructions, improper maintenance, improper operation, or
as a result of system integration or installation not explicitly approved in writing
by Air-Weigh.
Air-Weigh and its resellers shall have no responsibility or liability for damages if
the purchaser or any other person alters the vehicle incorporating Air-Weigh
products. This limited warranty shall not apply to any product that has been
repaired or altered by anyone not employed by Air-Weigh or not operated in
accordance with the manufacturer’s printed material delivered with this product.
Air-Weigh hereby expressly disclaims any and all implied warranties of any
type, kind of nature whatsoever, and particularly any implied warranty of
merchantability or fitness for a particular purpose not expressly stated by AirWeigh in its printed material delivered with its products.
Some states do not allow the exclusion or limitation of incidental or
consequential damages. If such laws apply, the limitations or exclusions
contained in the terms and conditions of this Warranty may not apply. This
warranty gives you specific legal rights and you may also have other rights,
which vary state to state.
May be covered by U.S. Patent Nos. 5478974, 5780782, 7478001
Foreign Patent Nos. 260494, 677998, 2122766
Copyright © 2004, 2006, 2007, 2010, 2011, 2012, 2013 by Hi-Tech Transport Electronics,
Inc. All rights reserved. Air-Weigh®, ComLink™, and Hi-Tech Transport Electronics are
trademarks or registered trademarks of Hi-Tech Transport Electronics, Incorporated.
Other brand, product, or service names listed in this document are the trademarks or
registered trademarks of their respective holders. Information contained in this literature
was accurate at time of publication. Product changes may have been made after
copyright dates that are not reflected in this document.
Procedure for Warranty Claims
1. For a warranty claim of an Air-Weigh product, customers
should get the part number, serial number, and failure
description of the failed item and call Air-Weigh Customer
Support. Air-Weigh will replace or repair units that have
failed due to workmanship, at the discretion of Air-Weigh. In
the event that Air-Weigh requests to examine product prior to
disposition, or for repairs or replacements, Air-Weigh
requires a Return Material Authorization (RMA) number to be
issued before the item is returned. Customers should contact
Air-Weigh’s Customer Support Department at (888) 4593247 for an RMA number. Please reference this RMA
number in all correspondence.
2. Claimed items shall be shipped freight pre-paid to: AirWeigh, Customer Support Department, 1730 Willow Creek
Circle, Eugene, Oregon 97402, USA. The Air-Weigh RMA
number shall appear on the outside of the return packaging.
3. Air-Weigh shall examine returned material within 30 days
after receipt, or sooner if mutually agreed upon. If Air-Weigh
determines that the part or assembly was defective in
material or workmanship and within the warranty period, AirWeigh will repair or replace the part or assembly and return
freight pre-paid. In the event Air-Weigh determines that the
part or assembly cannot be repaired or replaced and is within
the warranty period, a credit not to exceed the purchase
price will be issued to the Air-Weigh customer.
4. Air-Weigh Accounting will process a credit memo and notify
the Air-Weigh customer by email or fax. The Air-Weigh
customer will process a corresponding debit memo and notify
Air-Weigh Accounting.
5. If the part or assembly received by Air-Weigh does not meet
the requirements of the warranty program set forth above, at
the Air-Weigh customer’s request the part or assembly will
either be discarded, returned freight collect, or repaired or
replaced at the Air-Weigh customer’s expense and returned
freight collect.
1730 Willow Creek Circle • Eugene, Oregon 97402-9152 USA
P.O. Box 24308 • Eugene, Oregon 97402-0437 USA
Telephone (541) 343-7884 • Order Desk (888) 459-3444
Customer Support (888) 459-3247 • FAX (541) 431-3121
Hours of Operation: Mon-Fri, 8am – 5pm, Pacific Time
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