Self-Weighing Truck and Trailer Scales

™

Model AW5800 On-Board Scales

STEER AXLE

DEFLECTION SENSOR KIT

INSTALLATION GUIDE

For Use on Vehicles with Steel Spring Steer Axles

Please Read Before Installing

PN: 901-0059-000 Rev 7

Limited Warranty

For product failures due to material or manufacturing defects, Air-Weigh will replace or repair all air suspension components for up to 3 years from shipment date to the end-user Air-Weigh customer. These three-year components include:

Displays, ComLinks, Air Sensors, Power Cables, Air Sensor Assemblies, Air

Sensor Harnesses, and all other associated external components. Deflection

Sensors have a 2-year warranty. Air-Weigh assumes no responsibility for administering warranty claims directly with any third party end users.

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, particularly any implied warranty of merchantability or fitness for a particular purpose not expressly stated by Air-Weigh 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. 4832141, 5478974, 5780782, Foreign Patent Nos. 623635, 1305191,

260494, 677998, 2122766, 625697

Copyright © 2004, 2006, 2007 by Hi-Tech Transport Electronics, Incorporated. All rights reserved. Air-Weigh®,

ComLink™, WireLink™, Weight Gauge™, and Hi-Tech Transport Electronics are 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 date that are not reflected.

2

Part # 901-0032-000

Procedure for Warranty Claims

1. In the event 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.

Contact Customer Support Department at (888) 459-3247 for an RMA number. Please reference this RMA number in all correspondence.

2. Claimed items shall be shipped freight pre-paid to: Air-Weigh, 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, Air-Weigh 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) 3437884 • Order Desk (888) 459-3444

Customer Support (888) 4593247 • FAX (541) 431-3121

Hours of Operation: Mon-Fri, 8am – 5pm, Pacific Time www.Air-Weigh.com

3

Table of Contents

INTRODUCTION

......................................................... 5

Parts & Bill of Materials Referenced In This Guide

. 6

TOOLS REQUIRED

................................................... 7

SENSOR INSTALLATION OVERVIEW

...................... 8

GLUE INSTALLATION OVERVIEW DRAWINGS

.... 10

SENSOR INSTALLATION OVERVIEW DRAWINGS

11

ASSEMBLY INSTRUCTIONS FOR GLUE KIT

........ 13

BRACKET AND SENSOR INSTALLATION

INSTRUCTIONS

........................................................ 14

Deflection Sensor Specifications

........................... 32

APPENDIX A:

........................................................... 33

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INTRODUCTION

The Air-Weigh Steer Axle Deflection Sensor is a major component of several Air-Weigh Tractor/Truck Scale kits.

Properly installed, it allows the user to determine the weight on a spring-ride steer axle.

For the most accurate weighing, follow the installation procedures in this guide exactly.

See the user manual included with your kit for complete scale installation, calibration and operation.

You must have the ComLink and display installed and powered to be able to check A/D readings using the DIAGNOSTICS menu in the display. Alternately, you can also use the optional Field Deflection

Sensor Tester to get measurements directly at the sensor.

Do not move the vehicle until after alignment tool removal, Step #19.

Following sensor installation, do not calibrate until after the vehicle has been in normal operation for a week or 800 miles, whichever comes first. This allows for a break-in period for the sensor.

Do not operate the vehicle with the alignment tool in place.

The heavy calibration must be done using a maximum vehicle load.

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Parts & Bill of Materials Referenced In This Guide

Part Number Description

010-0069-00X SENSOR INSTALLATION KIT

Qty

1

010-9093-00X DEFLECTION SENSOR, INTERNAL AMPLIFIER,

METRIPACK 150, FEMALE, 12" 1

Bill of Materials for Sensor Installation Kit 010-0069-00X

Part Number Description Qty

010-0021-001 ADHESIVE APPLICATION CAULK GUN

110-0080-000 TAB, SS, CONN MOUNT, DFL SNSR

111-0001-00X BRKT ASSY,DEFL SENSOR, BONDED (see below)

120-0066-000 COV

ER ASSY, DEFL SNSR W/ “CAUTION" DECAL

133-0009-000 WASHER-FLT, .375 ID, PFC 9, THK, USS, STL, Y ZN PL 4

139-0011-000 CLAMP,BAND,4.5-6.5IN DIA,21IN LONG 5

145-0007-000 CABLE TIE, .30"X24", NYLON, BLKUV

145-4552-001 NYLON TIE, 7", T-50, NYLON, BLK

6

2

350-0035-000 IPA, PREP PADS

350-0038-XXX ADHESIVE

1

1

1

1

6

1

350-0039-00X STATIC MIXER NOZZLE, 6"

380-0004-001 SPLIT LOOM,0.50, FT

901-0059-000 INSTLL MANL, DEFL SNSR, STR AXLE

1

.09

1

Note: Teromix-6700 may be used as an alternative to the 3M epoxy PN 350-0038-xxx, see Appendix A for details.

Bill Of Materials for Bracket Assembly 111-0001-000

Part Number Description Qty

110-0073-001 ALIGNMT TOOL,DEFL SNSR 1

114-0002-00X MTG BRKT,DT,GLUED,7 DEG,2"W 2

131-0037-001 SCR-MACH,.375-24X2.25 HEX HD, STL, GR 8, Y ZN PL 2

132-0014-000 NUT-HEX, .375-24, GRD 8, Y ZN PL 2

350-0040-000 TAPE, VINYL, FOAM, 1/4", CLOSED CELL, FT .22

350-0041-000 TAPE, FILAMENT, 2.36” – 3” WIDE, FT .22

Optional items:

Part Number Description

1000 DEFLECTION SENSOR TEST DEVICE 1

6

TOOLS REQUIRED (customer provided)

Sander with 40-grit medium

Chalk or permanent marker

Flat blade screwdriver

9/16” wrench

Torque wrench, 20-80 ft-lb range

9/16” socket

Epoxy paint

Caulk gun

OPTIONAL

50 ml Manual Dispenser, Loctite PN 98472 LB-10985 – customer provided

Deflection Sensor Test Device, Air-Weigh PN 1000

The Field Deflection Sensor Tester, Air-Weigh P/N 1000, can be used to measure A/D readings of the deflection sensor without connection to the AW5801 Truck Scale

Comlink.

NOTE: A/D refers to the analog-to-digital conversion of the sensor reading.

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SENSOR INSTALLATION OVERVIEW

Welded Install

Note: Welding is the preferred method of installing the deflection sensor brackets.

The following instructions are applicable to all steer deflection sensor installs where the sensor brackets will be welded to the steer axle. The balance of the install should be completed per user’s manual included with your kit.

Material Needed

Alcohol or degreaser

Small grinder or sand paper

C-clamp

ARC or wire welder

Epoxy paint

A. Prepare Axle for welding and bracket placement

1. Clean center of axle in preparation for sensor bracket placement. a) Measure and mark center of axle. b) Clean axle on both sides of the center mark in an area wide enough to encompass brackets.

1) Use alcohol or degreaser to remove grease.

2) Sand off any paint in the area.

2. If not already assembled, attach alignment tool to the two brackets

3. Remove foam strip from the bottom of bracket (weld only).

4. Center bracket on axle

5. Use C-clamps to hold bracket in place.

8

6. Weld bracket (see Step B). Allow to cool before removing clamps and alignment tool.

7. Apply epoxy paint to welded area; let dry before proceeding with sensor mounting.

B. Weld Bracket

1. Weld a full bead on front and back of each bracket piece.

2. Allow to cool before removing clamps and alignment tool.

3. Do not operate vehicle with alignment tool in place.

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Glue Install – alternative to welding

Mark the center of the axle and prepare it for glue.

Apply glue to the bottom of the bracket assembly.

Mount bracket assembly on the axle with band clamps.

Tighten the band clamps and let the glue cure.

Apply epoxy paint to glue and axle seam, let dry.

Mount the sensor and mounting tab to the brackets.

Connect the cables and mount to the tab.

Route the extension cable through the firewall.

Check for sensor readings in range.

Mount the cover over the sensor and brackets.

GLUE INSTALLATION OVERVIEW DRAWINGS

10

SENSOR INSTALLATION OVERVIEW DRAWINGS

Note: Sensor assembly instructions are the same for welded or glued bracket installation (the following diagrams show glued brackets).

11

Alternate Step 2 and 3: Passenger Side Install - Cover.

12

Air-Weigh recommends the following install procedure:

1. Weld or glue sensor bracket to axle.

2. While weld is cooling or glue is curing, mount in-cab components.

3. Continue deflection sensor install after weld has cooled or glue has cured.

4. Apply epoxy paint to glue and axle seam; let dry.

ASSEMBLY INSTRUCTIONS FOR GLUE KIT 010-0069-00X

1. Break tab off glue cartridge.

2. Slide glue into sleeve, align correctly (one side has a larger diameter).

3. Insert blue plunger into glue pack, align correctly (one side has a larger diameter).

4. Insert nozzle into glue cartridge. Twist to secure.

5. Insert glue cartridge assembly into caulk gun.

6. Press trigger until glue flows from the nozzle freely.

13

BRACKET AND SENSOR INSTALLATION INSTRUCTIONS

Note: Prior to bracket installation, peel off the coating from the bottom of the bracket assembly (PN 111-0001-

00X).

Figure 1

1. Axle and bracket preparation.

Mark the center of the steer axle (Figure 1).

2. Mark the top of the axle at 2 3/8 inches on either side of center. Clean the entire 4 3/4 inch wide area inside the marks with (2) of the supplied alcohol pads (350-0035-000).

You must clean the axle with alcohol before you start sanding and after you finish sanding for glue installs.

14

Figure 2

3. With 40-grit medium, sand the portion of the axle just marked and cleaned so that it is free of paint and other residues. Clean the area just sanded with (1) of the supplied alcohol pads (Figure 2).

Figure 3

4. Re-mark the center of the steer axle (Figure 3).

15

Figure 4

5. Clean the underside of the bracket assembly (111-0001-

000) with (1) of the supplied alcohol pads (Figure 4).

Ensure that the bracket assembly bolts are only loosely fastened to the nuts, so that the alignment tool (110-0073-

000) has a slight amount of free play. Leave the foam strip on the bottom attached to the bracket assembly .

6. Adhesive application.

The working time of the glue at

73°F is about 10 minutes.

7. Assemble the Glue Kit (010-0069-00X) using the

Adhesive Application Kit (010-0021-00X) and the supplied duo-pak glue cartridge (350-0038-XXX) as per page 13.

Note: See Appendix A page 30 if using Teromix-6700 adhesive.

16

Figure 5

8. Dispense and discard a small amount of adhesive to be sure both sides of the glue cartridge are flowing evenly and freely. (Figure 5)

Figure 6

9. Following the adhesive manufacturer’s instructions, apply the adhesive liberally to the bottom of the bracket assembly

(Figure 6). Do not remove the foam strip from the bottom of the bracket.

Ensure that there is no adhesive in the bracket channels or mounting bolt holes. Completely remove any that may have been put there accidentally.

Remove and discard the glue cartridge when finished.

17

Figure 7

10. Mounting the brackets on the axle.

Place the bracket assembly in the center of the axle (Figure 7). Make sure the center mark on the alignment tool lines up with the center mark on the axle.

Figure 8

11. Run a band clamp (139-0011-000) through the slot in the bottom of each bracket (Figure 8). Tighten the band clamps very firmly to secure the brackets in place, ensuring that the bracket assembly remains parallel to the axle length.

18

12. The band clamps should be very tight. If necessary, to make the bracket assembly parallel to the axle length, loosen the band clamps and readjust the bracket assembly.

Then retighten the band clamp.

13. Remove the filament tape (350-0041-000) from the top of the bracket assembly and discard.

14. Temporarily unscrew one of the bolts (131-0037-001) in the bracket assembly from its nut (132-0014-000) and remove the bolt from the bracket assembly. Ensure the unfastened side of the alignment tool lifts easily in and out of the bracket. If it binds, loosen one or both band clamps so the brackets can be lined up and the alignment tool has free play.

15. Reset the alignment tool and restore the bolt into the bracket assembly and loosely fasten with its nut.

16. Remove any excess adhesive in the area around the brackets, to ensure proper clearance when installing the cover in the procedure’s final steps.

17. Allow time for the adhesive to cure, according to the following table:

Ambient Temperature

32° F (0° C)

54° F (12° C)

72° F (22° C)

Cure time is 24 hours.

Fixture Time

6 Hours

3 Hours

2 Hours

19

Install comlink and display gauge in cab at this time. Return to sensor installation after glue has cured. Do not move the vehicle with the alignment tool installed.

19. Remove the alignment tool from the brackets. It should fit loosely. Save the two 3/8 bolts (131-0037-001) and 3/8 nuts (132-0014-000) for re-use during installation of the

Deflection Sensor. Apply epoxy paint on glue area and axle to cover surface where glue bonds to axle and let dry.

20. Clean the bracket channels with (1) of the alcohol pads.

21. Sensor insertion.

Clean the sensor ends (010-9089-

000) with the (1) remaining alcohol pad.

22. Insert the sensor with its cable extending away from the side of the vehicle where you ’ll route the sensor extension cable to the firewall. The “ TOP ” lettering at the opposite end should face up . (See Step 2 on page 8 in the Installation

Overview Drawings, showing an installation with routing planned on the driver side; or Alternate Step 2 on page 9 in the Installation Overview Drawings showing an installation with routing planned on the passenger side.)

Figure 10

20

23. Mount the sensor in the channels. Align the sensor with the bracket holes (Figure 10, previous page).

24. Place a 3/8" ID flat washer (133-0009-000) on one of the 3/8" x 2 1/4" bolts (131-0037-001) saved in Step 16.

Driver Side Cable Run

Figure 11-A

Note: See 26-P, page 23, for passenger side cable run.

25-D. Driver side cable run.

Insert one of the bolts with washer through the bracket hole on the sensor end without the TOP label on it, from the front of the vehicle to the rear.

(Figure 11-A)

21

Figure 11-B

Insert the second bolt through the connector assembly bracket tab (110-0080-000), then through the 3/8” ID flat washer. Slide bolt through the bracket hole, from the front of the vehicle to the rear. Ensure the tongue and tab extend around the sensor end. (Figure 11-B)

22

Note: See 25-D, page 21, for driver side cable run.

Figure 12-A

26-P. Passenger side cable run.

Insert one of the bolts with washer through the bracket hole on the sensor end without the TOP label on it, from the front of the vehicle to the rear. (Figure 12-A)

Figure 12-B

23

Place a 3/8” ID flat washer on the second bolt. Slide the second bolt through the bracket holes from the front of the vehicle to the rear. Place a washer, then connector assembly bracket tab (110-0080-000), on bolt. Ensure the tongue and tab extends around the sensor end. (Figure 12-

B, previous page)

27. Place a hex nut on each bolt and hand-tighten.

When tightening the sensor mounting bolts, you must torque the nut, not the bolt head.

28. Tighten the nut on the cable end of the sensor to 25 ftlbs of torque. Use torque wrench on the nut, not on the bolt head.

Torque will be increased in Step 30.

29. Tighten the nut on the non-cable end of the sensor to

25 ft-lbs of torque. Use torque wrench on the nut, not on the bolt head.

Torque will be increased in Step 31.

30. Tighten the nut on the cable end of the sensor to 50 ftlbs of torque. Use torque wrench on the nut, not on the bolt head.

31. Tighten the nut on the non-cable end of the sensor to

50 ft-lbs of torque. Use torque wrench on the nut, not on the bolt head.

Check A/D readings at this time using the display in the cab (comlink and sensor must be connected to display and powered up) or the Deflection Sensor Test

Device per Step 37.

24

NOTE: A/D refers to the analog-to-digital conversion of the sensor reading.

If the reading is below 750 , or there is no reading at all follow these steps to exert a pre-load on the sensor: a. Loosen the nut on the non-cable end of the sensor. b. Insert a wedge (i.e. a flat-blade screwdriver) under the non-cable end of the sensor until an appropriate

A/D reading is reached, for example:

Steer – 1000 (±250) c. Tighten nut on non-cable end of sensor to 25 ft-lbs. If

A/D readings are still within range, remove wedge and check A/D readings. Proceed with Step 30.

If the reading is above 1250: d. Loosen the nut on the non-cable end of the sensor. e. DO NOT WEDGE the sensor, lightly press on the top of the non-cable end to change A/D reading. f. Tighten nut on non-cable end of sensor to 25 ft-lbs.

Check A/D readings; if they are below 750 repeat

Steps 31 a - c. If they are above 1250, repeat Steps

31 d - f. If within range proceed with Step 32.

If using the Deflection Sensor Test Device: Before connecting the sensor to the sensor extension cable, check

A/D readings and adjust if necessary at this time according to Step 37 (see page 27). Otherwise, proceed with next step of installation.

25

Figure 13

32.

Assembling the connectors.

Connect the sensor connector to the 15' sensor extension cable (014-1500-028) to form a connector assembly (Figure 13).

Figure 14

33. Mount the connector assembly on the connector assembly bracket tab by inserting the tab in the grooves on the sensor extension cable connector. The connector grooves are on the side opposite the installed connector position assurance tab (Figure 14).

26

34. Route the sensor extension cable across the axle, along the frame, and through the cab firewall.

NOTE: Be sure to leave enough slack in the cable between the axle and frame to allow for axle movement.

35. When the AW5801 Truck Scale ComLink is mounted, connect the sensor extension cable to the appropriate

AW5801 port as follows:

For a single Drive Axle sensor, connect

Steer Axle sensor to AW5801 Port B;

For dual Drive Axle sensors, connect

Steer Axle sensor to AW5801 Port C.

For more information about sensor port connections, see

Important Installation Instructions: Installing Sensor(s) for This Kit (901-0039-000) included in the Truck Scale kit documents package.

36. Refer to the Air-Weigh manual for the AW5800 Truck

Scale included in your kit. On your AW5800 Weight Gauge

Display, find the A/D reading for the Steer Axle. Check that the A/D reading for the Steer Axle is in the range 750 to

1250. Skip Step 37.

37. If using the Deflection Sensor Test Device - PN 1000 ,

A/D readings will be shown on a display after connecting per user instructions provided with tester. Follow Steps 27 – 31 for tightening the nuts on sensor. Acceptable A/D readings are:

Steer – 1000 (±250)

When readings are in the acceptable range, disconnect the test fixture and connect deflection sensor cable to sensor

27

extension cable. As in Step 34, route the sensor extension cable across the axle, along the frame, and through the cab firewall to the mounted AW5801 Truck Scale Comlink.

Connect the sensor connector to the 15' sensor extension cable (014-1500-028) to form a connector assembly.

NOTE: Check A/D readings, if they are below 750 repeat

Steps 31 a - c. If they are above 1250, repeat Steps 31 d - f.

If the previous adjustments do not bring the A/D readings into acceptable range then both nuts must be loosened and the process repeated from Step 28. The sensor cable may also need to be disconnected if using the Deflection Sensor Install

Test Fixture.

Following sensor installation, do not calibrate until after the vehicle has been in normal operation for a week or 800 miles, whichever comes first. This allows for a break-in period for the sensor.

Do not operate the vehicle with the alignment tool in place.

For calibration, refer to the Air-Weigh manual for the

AW5800 Truck Scale included in your kit.

38. Cover installation.

Very loosely install band clamps

(139-0011-000) around the axle on both sides of the installed sensor. Ensure that the band clamp encircles both the axle and the sensor extension cable.

28

Figure 15

39. Mount the cover on top of the sensor and sensor brackets so that the sensor cable is completely under the cover. The bracket band clamps should emerge from the cover’s side ports (Figure 15). The sensor extension cable should emerge from the cover’s end port on the side that you will be routing the cable to the firewall.

Figure 16

29

40. Slip each band clamp over the flange on the ends of the cover and tighten in place (Figures 16 – previous page - and 17).

Figure 17

Figure 18

41. Routing the cable.

Run the sensor extension cable along the rear of the axle towards the side of the truck,

30

securing with band clamp (139-0011-000). Place split loom

(380-0004-001) over the band clamp where the cable crosses it. Secure the cable to the band clamp with nylon ties (145-4552-001; Figure 18, previous page). Use additional 24” nylon ties (145-0007-000) as required to secure the cable.

Refer to the Air-Weigh manual for the AW5800 Truck Scale for complete Installation, Calibration and Operation of your

Air-Weigh On-board scale.

Following sensor installation, do not calibrate until after the vehicle has been in normal operation for a week or 800 miles, whichever comes first. This allows for a break-in period for the sensor.

Do not operate the vehicle with the alignment tool in place.

The heavy calibration must be done using a maximum vehicle load.

31

Deflection Sensor Specifications

Operating Temperature Range:

-40 to 85 Degrees C

Compensated Operating Temperature Range:

-10 to 40 Degrees C

Storage Temperature Range:

-40 to 85 Degrees C

Rated capacity:

*40,000 lbs Full Scale

Input:

Output range:

5 VDC +/- 10%

Output:

4.5 VDC +/- 5 % @ Rated Capacity

** 1.0 to 4.5 VDC +/- 5%

Environmental:

Nickel Plated Steel / IP rating = 65

* Depends on application; maximum deflection is 0.150 inches at rated capacity.

** No load = 1.0 VDC +/- 10% out. Full / maximum load = 4.5 VDC

+/- 10% out.

32

APPENDIX A:

Teromix-6700

Product Description

Teromix-6700 is a polyurethane-based two-component adhesive which cures at room temperature. Curing can be accelerated by increasing the temperature (e.g. IR radiator). The product is supplied in a convenient twin cartridge and is rapid-curing.

Teromix-6700 can be painted with normal commercial car paints.

Application Areas

Teromix-6700 is used in motor vehicle body repair shops for bonding customizing and body parts.

Examples of possible applications include:

– antiflutter/stiffening (motor hood with strut, roof skin and framing), wing and wheel housing

– bonding of plastic components such as glass fibre reinforced duromers (SMC, BMC/ZMC) to each other and to metals

– corrosion protection on hem flange joints.

Technical Data

Component A, Component B

Color: beige, black

Density: approx. 1.4 g/cm3 approx. 1.7 g/cm3

Solids (3 h at 100 C): > 98 % > 98 %

Mixing ratio by volume: 100 : 100

Mixture (components A + B)

Color: dark grey

Pot life (100 g, 23 C): approx. 10 mins

Tack-free time: approx. 30 mins

Solid to hand pressure: at 23 C approx. 2 hrs at 80 C approx. 10 mins

Curing time at 23 C: approx. 6 hours (85 % of final strength)

Shore A hardness: approx. 90

33

Shear Strength: approx. 23 MPa on

(measured after 2 d at 23 C): approx.13 MPa

Cross head speed: 100 mm/minute

Paintability: good

In service temperature range: -40 C to 80C

Short exposure (up to1 hour): 140 C

Pretreatment of the adhesion surfaces

The parts to be joined must be free from oil, grease, moisture, dirt and release agents.

One proven method of preparing the bonding faces of plastics is mechanical roughening of the surface (brushing, abrasive rubbing, sandblasting). Such mechanical treatment removes adhesioninhibiting surface layers (e.g. release agents). Metals may either be primed (e.g. cathodic EC, 2-component epoxy resin primer) or they should be grinded.

The Teromix system

The Teromix system consists of the Teromix hand gun, the efficient Teromix-6700 double cartridge and a mixer nozzle

(static mixer). Precise instructions are included with every pack.

Inserting the cartridge

Push the lock on the Teromix hand gun upwards and draw the piston bar back as far as the stop. Place the Teromix cartridge in the cartridge guide, unscrew the cap from the cartridge and screw on the mixer nozzle. Cut the end of the mixer nozzle to produce the desired size of bead.

Applying Teromix-6700

When the gun lever is operated, the material is forced through the mixer nozzle and the two components are automatically mixed.

(Do not use the first 2 cm of extruded adhesive bead, for these might not be perfectly mixed.) Teromix-6700 is applied directly onto the substrate without the need for any chemical primer. Any excess material should be removed immediately after application.

The cured adhesive within the mixer will seal the cartridge. A new mixer nozzle will have to be used if the cartridge is re-used.

34

Curing

The bonded joint can be worked mechanically after 2 hours at room temperature; a waiting period of 15 minutes is sufficient if an infra-red radiator is used with a temperature of 60 C. The infrared radiator should be placed at a distance of ca. 30 cm from the bond. Object temperature 60 C.

Cleaning

Fresh, non-cured material (e. g. for cleaning tools, cleaning contaminations on the substrates etc.) may first be removed dry and then cleaned off with a suitable solvent (e.g. acetone, ethyl acetate, Cleaner-A, Cleaner-D). Cured adhesive can only be removed mechanically.

35

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 www.Air-Weigh.com

36