Air Weigh AW5800 Installation, Calibration And Operations Manual
Self-weighing truck and trailer scales, on-board scales tractor scale system
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Summary of Contents for Air Weigh AW5800
- Page 1 ™ Self-Weighing Truck and Trailer Scales Model AW5800 On-Board Scales TRACTOR SCALE SYSTEM Installation, Calibration and Operations Manual Please Read Before Installing PN: 901-0038-000 Rev14...
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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 TRACTOR SCALE KIT COMPONENTS 5800 TRACTOR SCALE SYSTEM OVERVIEW INSTALLATION Route Air Line from Suspension (Optional) Installing Air Pressure Sensor(s) Installing Deflection Sensors Kit configuration Sensor Assignment Cutting Hole In Dash and Mounting Weight Gauge Connecting the ComLink Wiring Harness Mount ComLink Behind Dash Secure Cables and Air Lines. - Page 5 QUICK REFERENCE MENU DIRECTORY MENU OPERATIONS AND DEFINITIONS Weight Display Overview WEIGHTS ALARMS PRINT REPORT CALIBRATION SYS CONFIG SET PIN# DISPLY TYPE SCALE TYPE LBS/KGS SHOW / HIDE BACKLIGHT MODEL NUMBER DATA REPORT SHOW GVW SHOW STEER SHOW HELP SYSTM STATUS ALRM WEIGHTS TEST ALARM A/D READINGS...
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Page 6: Tractor Scale Kit Components
AIR-WEIGH TRACTOR SCALE KIT Tractor Scale Kit, AW5800, Air Pressure Drive, Calculated Steer, APP3 Includes all items listed below: Hardware Kit, AW5801, Truck PN 010-0063-000 Sensor Assembly, Air Pressure, 5V, 1/4" Push-On Brass Fitting PN 010-9008-00x x – denotes a variable... - Page 7 Cable, AW5801, Sensor, 3' PN 014-xx00-012 x – denotes a variable number Card, Sensor Config, AW5800, BOM level PN 901-0039-000 Doc and Label Kit, AW5800 Truck PN 901-0038-000 Tractor Scale Display, AW5800 PN 050-5800-00x x – denotes a variable number...
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Page 8: 5800 Tractor Scale System Overview
The AW5800 scale display can show up to nine axle groups on one tractor/trailer combination. Once the AW5800 is calibrated for weight, it is not necessary to recalibrate unless the suspension characteristics change. - Page 9 This will improve repeatability and accuracy. Any tractor equipped with an AW5800 Tractor Scale will automatically display trailer weight data from Air-Weigh equipped trailers. No re- calibration or trailer ID entry is required. No special tractor-trailer connection is necessary, because trailer weight data is transmitted over the vehicle‘s existing 7-wire cord (J-560) without any interference.
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Page 10: Installation
INSTALLATION Route Air Line from Suspension (Optional; if Tractor Suspension gauge already exists in dash skip to Installing Air Pressure Sensors) Route a 1/4 inch air line from the airbag suspension to the dash. Use a 1/4 inch brass street-T at the top of a convenient drive axle suspension air bag to access air pressure. -
Page 11: Installing Air Pressure Sensor(S)
Install brass fitting (150-4083-000) into rear of bulkhead fitting. Run air line (380-0050-000) from brass fitting in rear of tractor bulkhead up into dash to within 3‘ of comlink location. Secure with wire-ties. Connect sensor assembly (reference Installing Air Pressure Sensor(s), below) to end of air line in dash. Using sensor cable, connect sensor to appropriate port in comlink (Sensor B, or C if dual leveling valves). -
Page 12: Kit Configuration Sensor Assignment
TRACTOR KIT CONFIGURATION SENSOR ASSIGNMENT Number Sensor Installed Sensor Type ComLink on this Suspension AP = Air Pressure Sensor Sensor See Kit Part DS = Deflection Sensor Number for Cable Input HY = Hydraulic Sensor Jack Model Number 5800 Drive Sensor A Drive, Dual Height Control Valves or other Sensor A... -
Page 13: Model Number
DEDICATED TRAILER KIT CONFIGURATION SENSOR ASSIGNMENT Model Number Sensor Installed Sensor Type ComLink on this Suspension AP = Air Pressure Sensor Sensor See Kit Part DS = Deflection Sensor Number for Cable Input HY = Hydraulic Sensor Jack Model Number Drive Sensor A 5840... -
Page 14: Cutting Hole In Dash And Mounting Weight Gauge
Cutting 2-1/8-Inch Hole In Dash and Mounting the Display Gauge Select a location for the scale on the dash panel with at least 3‖ clearance behind the dash for the unit and its connections. A higher dash position provides better visibility. Make a 2-1/8-inch (2.06‖) hole at that location. -
Page 15: Mount Comlink Behind Dash
Connect the 4-pin sensor cable(s) to the ComLink Sensor Inputs A, B, C, or D, as described in the System Description and Part List that came with your Air-Weigh scale kit. If you choose to connect an alarm, connect the alarm output wire to any self-grounded alarm device (buzzer, horn, light, etc.). -
Page 16: Secure Cables And Air Lines. Re-Assemble The Dash
Secure Cables and Air Lines. Re-assemble the dash. Excess wire and harness should be coiled and wire tied. Wires, air lines, and sensor assemblies should be wire tied to other secure harnesses to prevent damage due to vibration. Re-assemble the dash. Turn-on the key and perform a final system check. -
Page 17: Calibration
ADJUST function (See page 23). Preliminary Considerations The accuracy of the AW5800 Tractor Scale depends on the accuracy of the certified scale used to calibrate or check-weigh. Ensure that the in- ground scale is reliable, recently certified and in good repair. It is... - Page 18 If possible, deflate the suspension for 5 to 10 seconds, and then re-inflate to factory-specified ride height Once the AW5800 Tractor Scale is calibrated, it is not necessary to re- calibrate unless the suspension characteristics change. Assigning a PIN number during the system set-up process will protect the calibration procedure from tampering.
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Page 19: Calibrating The Tractor Scale Overview
One decal should be on the 5th wheel slider assembly and the other should be on the frame mounting with the points of the triangles together when calibrating and weighing. Separate left and right side Height Control Valves For tractor and trailer suspensions with dual Height Control Valves (air suspension with both right and left height control valves on the same axle group), tractor or trailer scale kits with dual sensor processors must be specified when ordering. -
Page 20: Manual Calibration Procedure
the bobtail tractor to the scale to re-weigh the steer and drive axles. Return to your level parking spot, no brakes, re-inflate the suspension, and then enter the empty axle weights into the Air-Weigh scale. Once you’ve entered both heavy and empty axle weights, the scale should be displaying the actual on-the-ground weight to within 300 lbs. -
Page 21: Heavy Weights
10. Using the up/down arrows <>, scroll to the proper empty weight identified from a certified scale ticket. Press <ENTER>. Press <ESC> to return to axle screen and choose another axle to calibrate. Press <ESC> repeatedly to return to the main menu. 11. -
Page 22: Calibration By Direct Entry Of Ratio And Offset
Calibration by Direct Entry of RATIO and OFFSET Values To use this method, you must first obtain the RATIO and OFFSET values from another AW5800 Tractor Scale on a tractor with identical suspension and 5th wheel position that already has been correctly calibrated. Then you can directly enter these values into the Tractor Scale you wish to calibrate. -
Page 23: Enter The Ratio And Offset
ENTER THE RATIO AND OFFSET Press <ESC> one or more times until the ―top menu‖ appears, with VIEW WEIGHTS blinking. Press the down arrow <> 2 times until PRINT, SETUP begins blinking. Press <ENTER>. Press the down arrow <> 1 time until SYSTEM SETUP begins blinking. -
Page 24: Adjust Weights Worksheet
scale. Follow the steps given in OBTAIN THE RATIO AND OFFSET, above, to confirm that the scale accepted these values correctly. Finally, perform a check-weigh with a reliable ground scale to compare weights. In some cases, optional tires, wheels, and axle systems may cause the scale‘s initial accuracy to be unacceptable. -
Page 25: Operations
12. Press <ESC> repeatedly to return to the main menu. OPERATIONS Once calibrated, your Air-Weigh AW5800 Tractor Scale is ready to display weights in 20lb (20kg) increments, and be accurate to within 300lbs (140kgs) of a certified ground scale. Continued accuracy is established by following a few simple rules before taking weight readings: Park the tractor and trailer on a level surface. -
Page 26: Functional Operatons
FUNCTIONAL OPERATIONS HOW-TO-WEIGH instructions HOW-TO-WEIGH instructions are displayed on the tractor scale in rotation with the actual weight screen. To turn off these instructions permanently: Press <ESC> one or more times until the ―top menu‖ appears, with VIEW WEIGHTS blinking. Press the down arrow <>... -
Page 27: Alarm Function
PIN back to ZERO will reset the scale to its original status of NO PIN needed. Alarm Function The Air-Weigh AW5800 Tractor Scale has a 12V-24V 1.0 amp output alarm. To use the alarm feature, attach the gray alarm output wire stemming from the Tractor ComLink harness to a user-supplied alarm. It will activate when a programmed warning weight or alarm weight limit is reached. -
Page 28: Alarm Function Programming Procedure
settings, the alarm function resets. The alarm feature is now ready for the next load. Alarm Function Programming Procedure ALARM WEIGHTS Press <ESC> one or more times until the ―top menu‖ appears, with VIEW WEIGHTS blinking. Press the down arrow <> 1 time until ALARMS begins blinking. Press <ENTER>. -
Page 29: Languages
TURN ON/OFF portion of the ALARMS menu and change the (Now ON) back to a (Now OFF). LANGUAGES The AW5800 offers a choice of language display: Press <ESC> one or more times until the ―top menu‖ appears, with VIEW WEIGHTS blinking. - Page 30 Press the down arrow <> 1 time until SYS CONFIG begins blinking. Press <ENTER>. DISPLY SETUP is now blinking. Press <ENTER>. Press the down arrow <> 2 times until BACKLIGHT begins blinking. Press <ENTER>. Press the <> buttons to select the desired time period. Press ENTER.
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Page 31: Quick Reference Menu Directory
QUICK REFERENCE MENU DIRECTORY AW5800 Scale System CALIBRATION REQUIRED TRAILER ALARMS BEFORE USE WARN WEIGHT ALARM WEIGHT TURN ALARMS ON/OFF OVERVIEW PRINT, SETUP WEIGHTS SETUP only shows if data stream ALARMS PRINT REPORT ( if not data stream) PRINT, SETUP... -
Page 32: Menu Operations And Definitions
MENU OPERATIONS AND DEFINITIONS Press the <ESC> button one or more times to reach the Top Menu. Use the <> and <> buttons to scroll to new selections. Refer to the Quick Reference Menu Directory above for the entire menu structure. Weight Display Overview Use the up/down arrows <>... -
Page 33: Calibration
30 minutes. SCALE TYPE MENU MODEL NUMBER – Used to change the AW5800 Truck Scale configuration. For instance, when adding an additional sensor at a later date. See the section on Installing an Air Pressure Sensor for the model numbers that are used at this menu. -
Page 34: Show Gvw
Users‖ and consult Air-Weigh Support for more information on this subject. When DATA STREAM is selected menu changes occur: In the first level menu screen, PRINT,SETUP will change to SETUP. The second level menu screen PRINT REPORT is no longer an option choice. -
Page 35: A/D Readings
Use the up/down arrows <> to scroll between the axle groups. SYSTEM TROUBLE SHOOTING The Air-Weigh AW5800 Tractor Scale system is extremely self-sufficient. To operate correctly, power and ground are the only tractor electrical connections needed. Ensure all connectors (male/female) make a good connection and at least 9.5 volts is entering the system. - Page 36 All other faults can be identified internally through the DIAGNOSTICS display on the scale display. Press <ESC> one or more times until the ―top menu‖ appears, with VIEW WEIGHTS blinking. Press the down arrow <> 2 times until PRINT, SETUP begins blinking.
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Page 37: Incorrect Weight Readings
INCORRECT WEIGHT READINGS If weights are always off by the same amount, see the subsection ADJUST WEIGHTS in the CALIBRATION section, above. If weights are otherwise incorrect, including 0 (zero) or unstable, ensure that the sensor is connected to the Truck ComLink or Trailer Scale correctly. -
Page 38: Maintenance
Ride Height Symptoms: Scale readout accuracy varies from certified weight, by varying amounts. Solution: Proper ride height is the most important factor in ensuring accuracy. Ride height is normally defined as the vertical distance from the center of the axle to the bottom of the frame rail. This varies by vehicle and suspension make, so check the proper manual. -
Page 39: Customer Support
Connections: Periodically spray the 7-pin J-560 sockets and plugs with electrical cleaner. A good electrical connection is vital for proper operation. Make every effort to keep moisture out of the disconnect socket while the system is in operation. CUSTOMER SUPPORT If you cannot correct a problem, or you suspect you have a malfunctioning part, please contact Air-Weigh Customer Support at (888) 459-3247, Monday through Friday, 7 AM–5 PM Pacific... -
Page 40: Tractor/Trailer Communication
Obtaining good tractor/trailer scale communications: To help ensure good tractor scale / trailer scale communications, follow a simple rule in the installation of the 5801 Tractor Scale ComLink. This requires two resistance measurements, one for ground and an identical one for power, before applying the rule. - Page 41 The second measurement: Measure the resistance between the cable at the battery‘s positive (+) terminal on the one hand, and the common connection point between the tractor scale and trailer scale power wires on the other. Measurements should be made using an ohmmeter or multimeter.
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Page 42: Index Of Application Notes
Index of Application Notes The following Application Notes are available from Air-Weigh Customer Support for additional information on these subjects: 901-0069-000 - Dropping and hooking a 5802 Trailer Scale on a Trailer-Direct system 901-0070-000 - Dropping and hooking a 5802 Trailer Scale on a Two Trailer Direct system 901-0071-000 - Collecting and Entering Calibration 901-0072-000 - 5802 Trailer Scale, Load Distribution and Spread Tandem Axle Air... - Page 43 NOTES:...
- Page 44 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, 7am – 5pm, Pacific Time www.Air-Weigh.com...
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