airweigh LoadMaxx Installation Manual

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LoadMaxx

Installation Guide

Hendrickson Drive Suspensions

Welded Steer and Drive Brackets

Air-Weigh Customer Support: 888-459-3247

PN 901-0155-002 R0

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Page 1 LoadMaxx Installation Guide Hendrickson Drive Suspensions Welded Steer and Drive Brackets Air-Weigh Customer Support: 888-459-3247 PN 901-0155-002 R0...
Page 2: Table Of Contents
Table of Contents About LoadMaxx for Hendrickson Suspensions......1 About Installation................1 Overview..................1 Tools Required.................2 Optional Tools................2 Installing the Steer Axle Sensor Bracket........3 Preparing the Steer Axle Sensor Brackets.......3 Welding the Bracket..............6 Adding a Protective Spray Paint Coating........7 Installing the Drive Axle Sensor Bracket........8 Assembling the Bracket to the Jig..........8...
Page 3 Installing the Steer Axle Sensor...........17 Installing the Drive Axle Sensor...........19 Setting the A/D Values..............20 Adjusting the A/D Readings............21 Final Sensor Torque..............22 Steer Axle Cover Installation............23 Limited Warranty................25 Procedure for Warranty Claims...........26 Notes....................27...
Page 4: About Loadmaxx For Hendrickson Suspensions
About LoadMaxx for Hendrickson Suspensions LoadMaxx is a weighing system for vehicles that works by using delection sensors and/or air pressure sensors. The sensors measure suspension lex or air pressure changes and converts that number into weight, which is displayed in the truck cab. Weight information, including axle group, net, and gross vehicle weights, is also displayed.
Page 5: Tools Required
Tools Required You will need the following tools to install the delection sensors on the steer and drive axles. • Sander/grinder • 40-grit medium sandpaper • Chalk or permanent marker • 22 MM combination wrench • Torque wrench • 22 MM socket and socket handle •...
Page 6: Installing The Steer Axle Sensor Bracket
Installing the Steer Axle Sensor Bracket Note: This section applies only to scales using the 5817 coniguration. The 5809 or 5810 conigurations do not include a steer axle sensor. If you are using one of these conigurations, skip this section and see the section on installing the drive axle sensor (page Preparing the Steer Axle Sensor Brackets 1.
Page 7 Sanding the Steer Axle 4. Re-mark the center of the steer axle. 5. Verify that the bracket contact pads it 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.
Page 8 7. If the brackets have protective tape on them, remove the tape from around the bottom of the bracket assembly. Removing the Protective Plastic Strips 8. Clean the underside of the bracket assembly with one of the supplied isopropyl alcohol pads. Cleaning the Bottom of the Bracket Assembly...
Page 9: Welding The Bracket
Welding the Bracket Note: 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. Use C-clamps(NOT PICTURED) to hold the bracket in place.
Page 10: Adding A Protective Spray Paint Coating
3. 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. Do NOT weld the sides of the bracket, only the edges indicated below. Air-Weigh recommends that you use equipment similar to Miller Shopmaster 300 AC/DC;...
Page 11: Installing The Drive Axle Sensor Bracket
Installing the Drive Axle Sensor Bracket Assembling the Bracket to the Jig Note: You must make sure that the frame rail will not hit the top of the delection 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 a 1/2 inch more than the distance from the top of the bracket to the frame rail above it.
Page 12 3. Make sure both alignment pins are touching the J-bracket. 4. Securely tighten the J-bracket to the jig assembly. 5. Repeat the above steps using a second J-Bracket. Ensure all edges are parallel and at the same height. Completing the J-Bracket Assembly...
Page 13: J-Bracket Placement And Surface Preparation
J-Bracket Placement and Surface Preparation 1. Place the appropriate spacer (see Table below) against the bar pin end on either the front or the back of the equalizing beam. Put the J-bracket assembly against the spacer onto the equalizing beam. Table: Spacer for Speciic Suspension Type Hendrickson HN462/463 Hendrickson HAULMAXX...
Page 14 2. Hold the J-bracket assembly irmly on the suspension and mark the area inside the two large holes of each J-bracket. 3. Remove the J-bracket assembly and set it aside. 4. Using a sander or grinder with 40-grit sandpaper, clean a wide area around the marked areas until only bare metal is visible.
Page 15: Welding The J-Bracket
Welding the J-Bracket 1. Using the appropriate spacer, place the J-bracket assembly back on the walking beam. 2. Using two C-clamps, secure the bracket assembly to the walking beam. 3. Using a MIG or ARC welder, tack-weld the two large holes (top, bottom, left, right).
Page 16: Routing Cables
Routing Cables 1. Route the 20’ steer extension cable and the 40’ drive extension cable along their respective axles and the frame, and then through the cab irewall. Leave enough length for sensor connections. If at all possible, route along an existing wire harness.
Page 17: Installing The Comlink And Display
Installing the ComLink and Display The Optional Universal Mounting Pod can be used for installations where there is no space in the dash to mount the scale display. Preparing the Cab Display for Installation 1. Select a location for the display (1) on the dash panel (5) with at least 3”...
Page 18: Mounting The Comlink
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. The ComLink module should be oriented with the connectors facing downward and installed by either one of the following methods, using the hardware provided: Use zip ties through the holes in the ComLink module mounting ears to secure it to any appropriate wire harness...
Page 19: 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. Power and Ground Table White Wire Vehicle Chassis Ground Blue/Black Wire with In- 12VDC or 24VDC Key Line Fuse Hot Power...
Page 20 Installing and Adjusting the Steer Axle Sensor 1. Remove the alignment tool from the brackets. Retain the nuts and bolts. 2. 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 irewall.
Page 21 5. Insert the second bolt through the second bracket hole so that the bolthead is secured in the manufactured bolthead holder.. Hand-tighten the nut. Add Loctite, or other threadlocker adhesive, to the bolts to prevent loosening and corrosion. Attaching the Sensor to the Bracket...
Page 22 Installing the Drive Axle Delection Sensor Once welding is complete, you can install the delection sensor. 1. Clean the mounting surface for the delection sensor and bracket. Ensure there is no paint where the sensor is to be installed. 2. Attach the delection sensor to the beam with the cable exiting toward the center mount.
Page 23: Setting The A/D Values
A/D values. A/D refers to the analog-to-digital conversion of the sensor reading. This step will require the use of either the LoadMaxx in-dash display or the Delection Sensor Test box (P/N 1001). If using the LoadMaxx in-dash display, the scale must be installed and powered, and the Delection Sensor Extension Cable must be installed.
Page 24: Adjusting The A/D Readings
3. Verify the A/D reading using the display in the cab (start the ignition to power on the display), or the delection sensor test box. If the reading is within range (750-1250), continue Final Sensor Torque. If the reading to instructions for the is not within range, follow the instructions to adjust the A/D readings below.
Page 25 If the A/D reading is below 750, or there is no A/D reading at all, follow the steps below: 1. Loosen the nuts on both ends of the sensor 2. At the plastic nut where the cable enters the sensor, exert UPWARD pressure with your ingers until the A/D reading is between 750 and 1250.
Page 26: Steer Axle Cover Installation
Steer Axle Cover Installation 1. Mount the cover over the sensor and the brackets so that the sensor cable is completely under the cover. The sensor extension cable should emerge from the cover’s end port on whichever side you choose to route the cable. Ensure that the cable has free play and is not pinched by the sensor cover.
Page 27 Note: After you have installed delection sensors, do not calibrate until after the vehicle has been in normal operation for one week or 800 miles, whichever comes irst. Allowing for this break-in period will give you a more accurate calibration.
Page 28: Limited Warranty
Limited Warranty For product failures due to material or manufacturing defects, Air-Weigh will replace or repair all components for up to three 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 29: 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 30: Notes
Notes...
Page 31 Notes...
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...