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Air Weigh LoadMaxx Installation Manual

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LoadMaxx
Installation Guide
Ford F-750 Trucks
Air-Weigh Customer Support: 888-459-3247
1
PN 901-0154-000 R0

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Summary of Contents for Air Weigh LoadMaxx

  • Page 1 LoadMaxx Installation Guide Ford F-750 Trucks Air-Weigh Customer Support: 888-459-3247 PN 901-0154-000 R0...

  • Page 2: Table Of Contents

    Table of Contents TABLE OF CONTENTS ..............2 ABOUT LOADMAXX FOR F-750 ........... 4 ABOUT INSTALLATION ..............5 Overview ................5 Installation Components ............5 TOOLS REQUIRED ............... 6 Optional Tools ..............6 INSTALLING THE STEER AXLE SENSOR BRACKET ....7 Preparing the Steer Axle Sensor Brackets ......
  • Page 3 Installing the Deflection Sensor ......... 20 Setting the A/D Values ............22 A/D Reading is BELOW 750 ........... 22 A/D Reading is ABOVE 1250 .......... 23 Final Sensor Torque ............23 Steer Axle Finishing Touches ..........23 TESTING AND ADJUSTING THE DRIVE AXLE SENSORS ..26 A/D Reading is BELOW 750 ...........

  • Page 4: About Loadmaxx For F-750

    About LoadMaxx for F-750s LoadMaxx is a weighing system for vehicles that works by using deflection sensors and/or air pressure sensors. The sensors measure suspension flex or air pressure changes and convert that number into weight which is displayed in the truck cab..

  • Page 5: About Installation

    About Installation Overview There are three major components of the LoadMaxx scale that you will install: • Electronics: dash-mounted display, ComLink module, • Deflection sensor for the steer axle (vocational vehicles only) power cables and sensor extension cables • Deflection sensors for the suspension...

  • Page 6: Tools Required

    Tools Required You will need the following tools to install the deflection sensors on the steer and drive axles. • • Sander/grinder • 40-grit medium sandpaper • Chalk or permanent marker • Flat-blade screwdriver • Combination wrench • Torque wrench •...

  • Page 7: Installing The Steer Axle Sensor Bracket

    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 Mark AW5800-1024 Fig. 2: Marking the Center of the Steer Axle 2. Using chalk or permanent marker, mark the top of the steer axle 3 inches on either side of the center mark (6 inches in total).
  • Page 8 Alcohol Pad AW5800-1022 Fig. 3: Cleaning and Sanding the Steer Axle Fig. 5: Cleaning the Bottom of the Bracket Assembly 4. Clean the underside of the bracket assembly with one of the supplied isopropyl alcohol pads (Fig. 5). 5. Verify that the bracket contact pads fit into the sanded area and that no axle paint is left under the pad.

  • Page 9: Welding The Bracket

    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.

  • Page 10: Adding A Protective Spray Paint Coating

    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 the steer axle bracket from delaminating due to corrosion, we recommend you spray paint around the base of the bracket.

  • Page 11: Installing The Drive Axle Sensor

    Installing the Drive Axle Sensor Assembling the Bracket to the Jig 1. Ensure the alignment pin of the bracket mounting jig is touching the bracket (Fig. 11). 2. Tighten the supplied bolt to the jig assembly securely using a wrench. 3.

  • Page 12: Surface Preparation

    Fig. 12: Completing the Bracket Assembly Surface Preparation 1. Hold the bracket assembly firmly on the suspension and mark the area inside the two large holes with a permanent marker. 2. Remove the bracket assembly and set it aside. 3. Using a sander or grinder with 40-grit sandpaper, clean a wide area around the marked areas so that only bare metal is visible.

  • Page 13: Welding The Bracket

    Welding the Bracket 1. Place the bracket assembly on the suspension. Make sure the bare metal you sanded earlier lines up with the large holes in the brackets. 2. Using two C-clamps, secure the bracket assembly to the suspension (Fig. 12) 3.

  • Page 14: Installing The Deflection Sensor

    Installing the Deflection Sensor Once welding is complete, you can install the deflection sensor. 1. Clean the mounting surface for the deflection sensor and bracket with Brakleen®. Ensure there is no paint between the two surfaces to be mated. 2. Attach the deflection sensor to the beam with the cable exiting toward the center mount.
  • Page 15 NOTE: You must make sure that the frame rail will not hit the top of the deflection sensor bracket when the suspension is at maximum weight. As an approximation, ensure that the travel between the frame stop and the suspension is at least 1/2" more than the distance from the top of the bracket to the frame rail above it.

  • Page 16: Installing The Comlink And Display

    Installing the Comlink and Display Preparing the Cab Display for Installation 1. Select a location for the display (1) on the dash panel (5) with at least 3 inches of clearance behind the dash panel (5) for the unit and its connections. A higher dash position provides better visibility.

  • Page 17: Mounting The Comlink

    using 6 in-lbs. of torque. Do not over- tighten the mounting bracket nuts (4). Mounting the ComLink 1. Select a location behind the dash for the ComLink module, ensuring there is adequate access to the scale and the electrical connections. 2.

  • Page 18: Connecting Cables

    Connecting Cables The provided cables are used to connect the ComLink to the vehicle’s electrical system, to the dash display unit, and, if desired, to an alarm output. Table 2: Wiring Harness Hookup Power and Ground Table White Wire Vehicle Chassis Ground Blue/Black Wire with In-Line 12VDC or 24VDC Ignition Hot Power Fuse...

  • Page 19: Routing Cables

    Routing Cables 1. Route the 20-foot steer extension cable and the 40-foot drive extension cables along their respective axles and the frame, and then through the cab firewall. Leave enough length for sensor connections. If at all possible, route along an existing wire harness.

  • Page 20: Installing And Adjusting The Steer Axle Sensor

    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.
  • Page 21 6. Insert one bolt through the bracket hole on the sensor end with the word “TOP” on it (Fig. 16). 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.

  • Page 22: Setting The A/D Values

    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. Ensure the locking tabs on the connector plug engage completely (Fig. 18). Fig.

  • Page 23: A/D Reading Is Above 1250

    • Hand tighten the nut on the non-cable end of sensor and torque. 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. •...
  • Page 24 Fig. 19: Driver’s side orientation 3. 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. 20). Fig. 20: Passenger’s side orientation 4.
  • Page 25 Cover Flange Fig. 21: Placing the Cover 5. 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.

  • Page 26: Testing And Adjusting The Drive Axle Sensors

    Fig. 23: Cover with Sensor Extension Cable Band Clamp Steer Axle Split Loom Sleeving Sensor Extension Cable Nylon Tie AW5800-1037 Fig. 24: Securing the Sensor Extension Cable to the Axle Testing and Adjusting the Drive Axle Sensors 1. To assemble the connectors, insert the deflection sensor connector plug into the sensor extension cable connector OR...

  • Page 27: A/D Reading Is Below 750

    connect to the deflection sensor test box. Ensure the locking tabs on the connector plug engage completely (Fig. 25). Fig. 25: Assembling the Electrical Connector 2. Tighten both nuts and use a torque wrench to torque. NOTE: When tightening the bolts, ALWAYS check the torque on the nut, NOT the bolt head.

  • Page 28: A/D Reading Is Above 1250

    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.
  • Page 29 Figure 26. Completed Installation Your Air-Weigh scale installation is now complete. NOTE: After you have installed deflection sensors, do not calibrate until after the vehicle has been in normal operation for one week or 800 miles, whichever comes first. Allowing for this break-in period will give you a more accurate calibration.

  • Page 30: Limited Warranty

    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.

  • Page 31: Procedure For Warranty Claims

    Procedure For Warranty Claims ALL customers should irst contact Air-Weigh Customer Support Department at (888) 459-3247 for questions regarding the use, operation, repair or return of any Air-Weigh product. In the event Air-Weigh requests to examine the product prior to disposition OR for repair or replacement, Air-Weigh requires a Return Material Authorization (RMA) number be issued before the item is returned.
  • Page 32 1730 Willow Creek Circle • Eugene, OR 97402-9152 USA P.O. Box 24308 • Eugene, OR 97402-0437 USA Telephone (541) 343-7884 • Order Desk (888) 459-3444 Customer Support (888) 459-3247 • Fax (541) 431-3121 www.Air-Weigh.com...

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