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
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. Deflection Sensors have a 2-year warranty.
Procedure for Warranty Claims 1. 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. Please reference this RMA number in all correspondence. 2.
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 ........................................................
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. See the user manual included with your kit for complete scale installation, calibration and operation.
Parts & Bill of Materials Referenced In This Guide Part Number 010-0069-00X 010-9093-00X Description SENSOR INSTALLATION KIT DEFLECTION SENSOR, INTERNAL AMPLIFIER, METRIPACK 150, FEMALE, 12" Qty 1 1 Bill of Materials for Sensor Installation Kit 010-0069-00X Part Number 010-0021-001 110-0080-000 111-0001-00X 120-0066-000 133-0009-000 139-0011-000 145-0007-000 145-4552-001 350-0035-000 350-0038-XXX 350-0039-00X 380-0004-001 901-0059-000 Description Qty ADHESIVE APPLICATION CAULK GUN 1 TAB, SS, CONN MOUNT,
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 sensor without connection to the AW5801 Truck Scale Comlink.
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. Material Needed Alcohol or degreaser Small grinder or sand paper C-clamp ARC or wire welder Epoxy paint A.
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. 2. Allow to cool before removing clamps and alignment tool. 3. Do not operate vehicle with alignment tool in place.
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. Mount the sensor and mounting tab to the brackets. Connect the cables and mount to the tab. Route the extension cable through the firewall. Check for sensor readings in range. Mount the cover over the sensor and brackets.
SENSOR INSTALLATION OVERVIEW DRAWINGS Note: Sensor assembly instructions are the same for welded or glued bracket installation (the following diagrams show glued brackets).
Alternate Step 2 and 3: Passenger Side Install - Cover.
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. Break tab off glue cartridge. 2. Slide glue into sleeve, align correctly (one side has a larger diameter). 3.
BRACKET AND SENSOR INSTALLATION INSTRUCTIONS Figure 1 Note: Prior to bracket installation, peel off the coating from the bottom of the bracket assembly (PN 111-000100X). 1. Axle and bracket preparation. Mark the center of the steer axle (Figure 1). 2. Mark the top of the axle at 2 3/8 inches on either side of center. Clean the entire 4 3/4 inch wide area inside the marks with (2) of the supplied alcohol pads (350-0035-000).
Figure 2 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). Figure 3 4. Re-mark the center of the steer axle (Figure 3).
Figure 4 5. Clean the underside of the bracket assembly (111-0001000) 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 (110-0073000) has a slight amount of free play. Leave the foam strip on the bottom attached to the bracket assembly. 6. Adhesive application. The working time of the glue at 73°F is about 10 minutes. 7.
Figure 5 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) Figure 6 9. Following the adhesive manufacturer’s instructions, apply the adhesive liberally to the bottom of the bracket assembly (Figure 6). Do not remove the foam strip from the bottom of the bracket. Ensure that there is no adhesive in the bracket channels or mounting bolt holes. Completely remove any that may have been put there accidentally.
Figure 7 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. Figure 8 11. Run a band clamp (139-0011-000) through the slot in the bottom of each bracket (Figure 8). Tighten the band clamps very firmly to secure the brackets in place, ensuring that the bracket assembly remains parallel to the axle length.
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. 14. Temporarily unscrew one of the bolts (131-0037-001) in the bracket assembly from its nut (132-0014-000) and remove the bolt from the bracket assembly.
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. Apply epoxy paint on glue area and axle to cover surface where glue bonds to axle and let dry. 20.
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: See 26-P, page 23, for passenger side cable run. 25-D. Driver side cable run. Insert one of the bolts 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 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.
Note: See 25-D, page 21, for driver side cable run. Figure 12-A 26-P. Passenger side cable run. Insert one of the bolts 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.
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. (Figure 12B, previous page) 27. Place a hex nut on each bolt and hand-tighten. When tightening the sensor mounting bolts, you must torque the nut, not the bolt head. 28. Tighten the nut on the cable end of the sensor to 25 ftlbs of torque.
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. Insert a wedge (i.e. a flat-blade screwdriver) under the non-cable end of the sensor until an appropriate A/D reading is reached, for example: Steer – 1000 (±250) c. Tighten nut on non-cable end of sensor to 25 ft-lbs.
Figure 13 32. Assembling the connectors. Connect the sensor connector to the 15' sensor extension cable (014-1500-028) to form a connector assembly (Figure 13). Figure 14 33. Mount the connector assembly on the connector assembly bracket tab by inserting the tab in the grooves on the sensor extension cable connector. The connector grooves are on the side opposite the installed connector position assurance tab (Figure 14).
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 Steer Axle sensor to AW5801 Port B; For dual Drive Axle sensors, connect Steer Axle sensor to AW5801 Port C.
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. If they are above 1250, repeat Steps 31 d - f.
Figure 15 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.
40. Slip each band clamp over the flange on the ends of the cover and tighten in place (Figures 16 – previous page - and 17). Figure 17 Figure 18 41. Routing the cable.
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. Refer to the Air-Weigh manual for the AW5800 Truck Scale for complete Installation, Calibration and Operation of your Air-Weigh On-board scale.
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% Environmental: Nickel Plated Steel / IP rating = 65 * Depends on application; maximum deflection is 0.150 inches at rated capacity. ** No load = 1.0 VDC +/- 10% out.
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.
Shear Strength: approx. 23 MPa on (measured after 2 d at 23C): approx.13 MPa Cross head speed: 100 mm/minute Paintability: good In service temperature range: -40C to 80C Short exposure (up to1 hour): 140C Pretreatment of the adhesion surfaces The parts to be joined must be free from oil, grease, moisture, dirt and release agents. One proven method of preparing the bonding faces of plastics is mechanical roughening of the surface (brushing, abrasive rubbing, sandblasting).
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 60C. The infrared radiator should be placed at a distance of ca. 30 cm from the bond. Object temperature 60C. Cleaning Fresh, non-cured material (e. g. for cleaning tools, cleaning contaminations on the substrates etc.) may first be removed dry and then cleaned off with a suitable solvent (e.g.
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