Self-Weighing Truck and Trailer Scales

™

Air-Weigh Scales

Steer Axle Deflection Sensor

Kit Installation

Guide

For Use on Vehicles with Steel Spring Steer Axles

Please Read Before Installing

901-0145-003 R0

Table of Contents

ABOUT STEER AXLE DEFLECTION SENSORS ........................... 3

TOOLS REQUIRED ....................................................................... 4

INSTALLING THE STEER AXLE SENSOR BRACKET .................. 5

Preparing the Steer Axle Sensor Brackets ........................... 5

Assembling the Glue Kit ...................................................... 7

Applying the Adhesive ......................................................... 9

Securing the Bracket to the Steer Axle .............................. 10

Adding a Protective Spray Paint Coating ........................... 12

INSTALLING AND ADJUSTING THE STEER AXLE SENSOR .... 13

Installing the Deflection Sensor ......................................... 13

Setting the A/D Values ...................................................... 15

Steer Axle Finishing Touches ............................................ 17

LIMITED WARRANTY ................................................................. 22

PROCEDURE FOR WARRANTY CLAIMS ................................... 23

2

About Steer Axle Deflection Sensors

The Air-Weigh steer axle deflection sensor is a major component of several tractor and trailer truck scale kits. When it is properly installed, it allows the user to determine the weight resting on a spring-ride steer axle. This installation guide provides instructions for gluing the steer axle brackets and installing the deflection sensor. See the User Guide included with your kit for complete scale installation, calibration and operation.

Follow the installation procedures in this guide exactly for the most accurate weighing. This guide assumes that you have already installed the 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 access 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.

NOTE: If you are using a LoadMaxx scale, tractors using a

5849 scale configuration MUST have a fixed 5 th

wheel position.

Fig. 1: Major Components Location

3

Tools Required

You will need to supply to following tools to install deflection sensors on the steer and drive axles.



Sander/grinder



40-grit medium sandpaper



Chalk or permanent marker



Flat-blade screwdriver



9/16-inch combination wrench



Torque wrench, 20

– 80 ft-lb



9/16-inch socket and 3/8-inch socket handle



Caulking gun



Enamel spray paint, any color



Tape measure

Optional Tools



50 ml manual dispenser, Loctite

™, (customer provided)



Deflection sensor test box, p/n: 1001

4

Installing the Steer Axle Sensor

Bracket

Preparing the Steer Axle Sensor Brackets

1. Locate and mark the center of the steer axle (Fig. 2)

Center M ark

AW5800-1024

Fig. 2: Marking the Center of the Steer Axle

2. Using chalk or a permanent marker, mark the top of the steer axle 3 inches on either side of the center mark (6 inches in total). Clean this area. If the axle is heavily caked with dirt or grease, use Brakleen to remove the worst. Then clean the 6inch area using two of the alcohol pads supplied in the installation kit. See Fig. 3.

3. Using 40-grit medium sandpaper or a pneumatic grinder, sand the 6-inch area until nothing remains but bare metal.

We recommend that you partially sand down the mold line as well. See Fig. 3.

5

Alcohol Pad

AW5800-1022

Fig. 3: 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. 2)

6. Remove the protective plastic strips from the bottom of the bracket assembly (Fig. 4)

Fig. 4: Removing the Protective Plastic Strips

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Fig. 5: Cleaning the Bottom of the Bracket Assembly

7. Clean the underside of the bracket assembly with one of the supplied isopropyl alcohol pads (Fig. 5).

8. 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.

9. Once you have prepared the axle, test fit the new bracket on 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.

Assembling the Glue Kit

Use the following steps to assemble the glue kit. See Fig. 6.

1. Twist tab off glue cartridge.

2. Slide glue adhesive pack into sleeve. Be sure to align correctly; one side has a larger diameter.

3. Insert the blue plunger into the glue adhesive pack.

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

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Plunger Adhesive Pack Sleeve Nozzle

Caulking Gun

A W5800-1006

Fig. 6: Glue Kit

5. Press trigger to dispense glue. Before gluing axle, discard a small amount of adhesive to ensure both sides of the duo-pak glue cartridge are flowing freely (Fig. 7). Trim end of nozzle to allow better flow, if necessary.

.

Fig. 7: Clearing Duo-pak Adhesive

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AW5800-1007

Applying the Adhesive

Glue takes approximately 10 minutes at 73



F to set up. It will take between 2 and 3 hours in most climates to dry, and double that to cure completely. In very cold weather, glue may take up to 12 hours to dry.

NOTE: Adhesive expires within one month (or three months if refrigerated) of the scale ship date. Do NOT use Loctite glue if it is older than the expiration date printed on the side of the tube. The expiration date will include a month and a year; the glue is considered expired on the last day of the month printed on the tube. If glue is past its expiration date, please contact Air-Weigh for a replacement.

1. If the weather is below 60 degrees Fahrenheit (15.5 Celsius), we recommend that you warm the prepared axle area before gluing the bracket. Heat the prepared area of the axle using a heat gun, heat wrap or blanket, or a magnetic Katz heater until it is about room temperature (70 Fahrenheit or 20

Celsius). Do NOT use a blowtorch or other heating method to heat the axle, as this may cause warping and damage. When the axle is heated to room temperature, proceed to Step 2 below.

2. Hand-tighten the bolts securing the alignment tool to the bracket as much as possible to prevent improper spacing.

3. Apply the adhesive liberally to the side wings on the bottom of the bracket assembly (Fig. 8).

4. Place the bracket on the top center of the steel axle. Ensure the center of the bracket assembly aligns with the center mark you made earlier with the Sharpie.

5. Hold or clamp the bracket in place for approximately 5 to 10 minutes or until it feels secure.

6. Optional: Use a heat gun, heat wrap or blanket or magnetic Katz heater to accelerate the curing process of the adhesive. Do not install the deflection sensor until adhesive has fully cured. See Table 1 for curing times.

9

Table 1: Fixture and Cure Times for Adhesive

Ambient Temperature Fixture Time Cure Time

32° F (0° C)

54° F (12° C)

72° F (22° C)

12 Hours

3 Hours

2 Hours

24 Hours

6 Hours

4 Hours

Fig. 8: Applying Adhesive

NOTE: Do not cure adhesive at temperatures exceeding

190°F (88°C).

Securing the Bracket to the Steer Axle

1. Place a band clamp through the slot at the base of each bracket and wrap the band clamp around steer axle (Fig. 9).

2. Using a flat-blade screwdriver, tighten the band clamps securely in place. Make sure the mounting brackets remain exactly parallel to the steer axle. Band clamps should be very tight. If necessary, to keep the bracket assembly parallel to the steer axle, loosen the band clamps and readjust the bracket assembly. Retighten the band clamps.

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3. Allow time for the adhesive to cure. Refer to Table 1 for fixture and cure times. If you would like to accelerate the adhesive cure time, use a heat gun on a low setting to dry the adhesive.

NOTE: Do not move the vehicle until the adhesive has cured and the alignment tool removed.

Fig. 9: Securing Bracket on Steer Axle

11

Adding a Protective Spray Paint Coating

To prevent the steer axle bracket from delaminating due to 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 glued 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. 10: Spray Paint Coating

12

Installing and Adjusting the Steer

Axle Sensor

Before you install the steer axle sensor, make sure the steer axle adhesive is fixed and feels solid to the touch.

Installing the Deflection Sensor

1. Remove the alignment tool from the brackets. It should fit loosely. Retain the two 3/8-inch bolts and 3/8-inch 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. 11).

Fig. 11: Inserting the Sensor into the Bracket

5.

Align the steer axle sensor with the holes in the steer axle bracket assembly.

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6. Insert one bolt through the bracket hole on the sensor end with the word

“TOP” on it (Fig. 12). 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.

13).

Fig. 12: Attaching the Sensor to the Bracket

14

‘

Fig. 13: Installing the Connector Tab

Setting the A/D Values

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. 14).

Fig. 14: Assembling the Electrical Connector

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2. Tighten both nuts and use a torque wrench to torque to

30 ft-lbs.

NOTE: When tightening the bolts, ALWAYS torque the nut, NOT the bolt head.

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

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.

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

1250.



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 torque.

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.

16



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 torque.

Final Sensor Torque

4. Tighten both bolts to 60 ft-lbs.

5. Perform a final check of A/D values. If not within range, repeat the steps for altering A/D readings.

6. 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.

NOTE: Make sure there is enough slack in the sensor extension cable between the axle and the frame to allow for axle movement.

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. 15).

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Fig. 15:

Driver’s side orientation

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. 16).

Fig. 16:

Passenger’s side orientation

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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. 17).The sensor extension cable should emerge from the cover’s end port on whichever side you choose to route the cable.

Cover Flange

Fig. 17: 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. 18). Fig. 19 shows completed installation.

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Fig. 18: 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. 20. Use additional 24-inch nylon ties as required to secure the cable to the steer axle.

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Fig. 19: Cover with Sensor Extension Cable

Band Clamp

SteerAxle

Split Loom

Sleeving

Sensor Extension

Cable

Nylon Tie

AW5800-1037

Fig. 20: Securing the Sensor Extension Cable to the Axle

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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 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, and 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. 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.

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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) 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.

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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

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