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Air Weigh AW5800 Installation Manual

Steer axle deflection sensor kit
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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

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  • Page 1 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...

  • Page 2: Limited Warranty

    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.

  • Page 3: Procedure For Warranty Claims

    Procedure for Warranty Claims 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.

  • Page 4: Table Of Contents

    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 DRAWINGS11 ASSEMBLY INSTRUCTIONS FOR GLUE KIT ... 13 BRACKET AND SENSOR INSTALLATION INSTRUCTIONS ...

  • Page 5: Introduction

    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.

  • Page 6: Parts & Bill Of Materials Referenced In This Guide

    Parts & Bill of Materials Referenced In This Guide Part Number Description 010-0069-00X SENSOR INSTALLATION KIT 010-9093-00X DEFLECTION SENSOR, INTERNAL AMPLIFIER, METRIPACK 150, FEMALE, 12" Bill of Materials for Sensor Installation Kit 010-0069-00X Part Number Description 010-0021-001 ADHESIVE APPLICATION CAULK GUN 110-0080-000 TAB, SS, CONN MOUNT, DFL SNSR 111-0001-00X...

  • Page 7: Tools Required

    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...

  • Page 8: Sensor Installation Overview

    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.
  • Page 9 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.

  • Page 10: Glue Installation Overview Drawings

    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.

  • Page 11: Sensor Installation Overview Drawings11

    SENSOR INSTALLATION OVERVIEW DRAWINGS Note: Sensor assembly instructions are the same for welded or glued bracket installation (the following diagrams show glued brackets).
  • Page 12 Alternate Step 2 and 3: Passenger Side Install - Cover.

  • Page 13: Assembly Instructions For Glue Kit

    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.

  • Page 14: Bracket And Sensor Installation Instructions

    BRACKET AND SENSOR INSTALLATION INSTRUCTIONS Figure 1 Note: Prior to bracket installation, peel off the coating from the bottom of the bracket assembly (PN 111-0001- 00X). 1. Axle and bracket preparation. Mark the center of the steer axle (Figure 1). 2.
  • Page 15 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). 4. Re-mark the center of the steer axle (Figure 3). Figure 2 Figure 3...
  • Page 16 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.
  • Page 17 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) 9. Following the adhesive manufacturer’s instructions, apply the adhesive liberally to the bottom of the bracket assembly (Figure 6).
  • Page 18 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. 11. Run a band clamp (139-0011-000) through the slot in the bottom of each bracket (Figure 8).
  • Page 19 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.
  • Page 20 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.
  • Page 21 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. Figure 11-A Driver Side Cable Run Note:...
  • Page 22 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.
  • Page 23 Note: See 25-D, page 21, for driver side cable run. 26-P. Passenger side cable run. 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-A Insert one of the bolts Figure 12-B...
  • Page 24 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.
  • Page 25 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.
  • Page 26 32. Assembling the connectors. Connect the sensor connector to the 15' sensor extension cable (014-1500-028) to form a connector assembly (Figure 13). 33. Mount the connector assembly on the connector assembly bracket tab by inserting the tab in the grooves on the sensor extension cable connector.
  • Page 27 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...
  • Page 28 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.
  • Page 29 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.
  • Page 30 40. Slip each band clamp over the flange on the ends of the cover and tighten in place (Figures 16 – previous page - and 17). 41. Routing the cable. Run the sensor extension cable along the rear of the axle towards the side of the truck, Figure 17 Figure 18...
  • Page 31 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.

  • Page 32: Deflection Sensor Specifications

    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: 5 VDC +/- 10% Output: 4.5 VDC +/- 5 % @ Rated Capacity Output range: ** 1.0 to 4.5 VDC +/- 5%...

  • Page 33: Appendix A

    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.
  • Page 34 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.
  • Page 35 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 infra - red radiator should be placed at a distance of ca. 30 cm from the bond.
  • Page 36 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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