Air Weigh AW5800 User manual

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

2
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. Air-Weigh assumes no responsibility for
administering warranty claims directly with any third party end users.
The responsibility of Air-Weigh under this warranty is limited to the repair,
replacement, or credit of the defective part or assembly.
This warranty does not cover incidental or consequential damage to persons or
property caused by use, abuse, misuse, or failure to comply with installation or
operating instructions. This limited warranty does not apply to any product that has
failed due to accident, abuse, alteration, installation not consistent with printed
installation instructions, improper maintenance, improper operation, or as a result
of system integration or installation not explicitly approved in writing by Air-Weigh.
Air-Weigh and its resellers shall have no responsibility or liability for damages if the
purchaser or any other person alters the vehicle incorporating Air-Weigh products.
This limited warranty shall not apply to any product that has been repaired or
altered by anyone not employed by Air-Weigh or not operated in accordance with
the manufacturer’s printed material delivered with this product.
Air-Weigh hereby expressly disclaims any and all implied warranties of any type,
kind of nature whatsoever, particularly any implied warranty of merchantability or
fitness for a particular purpose not expressly stated by Air-Weigh in its printed
material delivered with its products.
Some states do not allow the exclusion or limitation of incidental or consequential
damages. If such laws apply, the limitations or exclusions contained in the terms
and conditions of this Warranty may not apply. This warranty gives you specific
legal rights and you may also have other rights, which vary state to state.
May be covered by U.S. Patent Nos. 4832141, 5478974, 5780782, Foreign Patent Nos. 623635, 1305191,
260494, 677998, 2122766, 625697
Copyright © 2004, 2006, 2007 by Hi-Tech Transport Electronics, Incorporated. All rights reserved. Air-Weigh®,
ComLink™, WireLink™, Weight Gauge™, and Hi-Tech Transport Electronics are registered trademarks of Hi-
Tech Transport Electronics, Incorporated. Other brand, product, or service names listed in this document are
the trademarks or registered trademarks of their respective holders. Information contained in this literature was
accurate at time of publication. Product changes may have been made after copyright date that are not
reflected.
Part # 901-0032-000

3
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 [phone] for an RMA
number. Please reference this RMA number in all correspondence.
2. Claimed items shall be shipped freight pre-paid to: Air-Weigh, Customer
Support Department, 1730 Willow Creek Circle, Eugene, Oregon 97402,
USA. The Air-Weigh RMA number shall appear on the outside of the
return packaging.
3. Air-Weigh shall examine returned material within 30 days after receipt, or
sooner if mutually agreed upon. If Air-Weigh determines that the part or
assembly was defective in material or workmanship and within the
warranty period, Air-Weigh will repair or replace the part or assembly and
return freight pre-paid. In the event Air-Weigh determines that the part or
assembly cannot be repaired or replaced and is within the warranty
period, a credit not to exceed the purchase price will be issued to the Air-
Weigh customer.
4. Air-Weigh Accounting will process a credit memo and notify the Air-
Weigh customer by email or fax. The Air-Weigh customer will process a
corresponding debit memo and notify Air-Weigh Accounting.
5. If the part or assembly received by Air-Weigh does not meet the
requirements of the warranty program set forth above, at the Air-Weigh
customer’s request the part or assembly will either be discarded,
returned freight collect, or repaired or replaced at the Air-Weigh
customer’s expense and returned freight collect.
1730 Willow Creek Circle • Eugene, Oregon 97402-9152 USA
P.O. Box 24308 • Eugene, Oregon 97402-0437 USA
Telephone [phone] • Order Desk [phone]
Customer Support [phone] • FAX [phone]
Hours of Operation: Mon-Fri, 8am –5pm, Pacific Time
www.Air-Weigh.com

4
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........................................................14
Deflection Sensor Specifications...........................32
APPENDIX A: ...........................................................33

5
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.
You must have the ComLink and display installed
and powered to be able to check A/D readings using
the DIAGNOSTICS menu in the display. Alternately,
you can also use the optional Field Deflection
Sensor Tester to get measurements directly at the
sensor.
Do not move the vehicle until after alignment tool
removal, Step #19.
Following sensor installation, do not calibrate
until after the vehicle has been in normal operation
for a week or 800 miles, whichever comes first. This
allows for a break-in period for the sensor. Do not
operate the vehicle with the alignment tool in place.
The heavy calibration must be done using a
maximum vehicle load.

6
Parts & Bill of Materials Referenced In This Guide
Part Number Description Qty
010-0069-00XSENSOR INSTALLATION KIT 1
010-9093-00X DEFLECTION SENSOR, INTERNAL AMPLIFIER,
METRIPACK 150, FEMALE, 12" 1
Bill of Materials for Sensor Installation Kit 010-0069-00X
Part Number Description Qty
010-0021-001 ADHESIVE APPLICATION CAULK GUN 1
110-0080-000 TAB, SS, CONN MOUNT, DFL SNSR 1
111-0001-00X BRKT ASSY,DEFL SENSOR, BONDED (see below) 1
120-0066-000 COVER ASSY, DEFL SNSR W/ “CAUTION" DECAL 1
133-0009-000 WASHER-FLT, .375 ID, PFC 9, THK, USS, STL, Y ZN PL 4
139-0011-000 CLAMP,BAND,4.5-6.5IN DIA,21IN LONG 5
145-0007-000 CABLE TIE, .30"X24", NYLON, BLKUV 6
145-4552-001 NYLON TIE, 7", T-50, NYLON, BLK 2
350-0035-000 IPA, PREP PADS 6
350-0038-XXX ADHESIVE 1
350-0039-00X STATIC MIXER NOZZLE, 6" 1
380-0004-001 SPLIT LOOM,0.50, FT .09
901-0059-000 INSTLL MANL, DEFL SNSR, STR AXLE 1
Note: Teromix-6700 may be used as an alternative to the 3M
epoxy PN 350-0038-xxx, see Appendix A for details.
Bill Of Materials for Bracket Assembly 111-0001-000
Part Number Description Qty
110-0073-001 ALIGNMT TOOL,DEFL SNSR 1
114-0002-00X MTG BRKT,DT,GLUED,7 DEG,2"W 2
131-0037-001 SCR-MACH,.375-24X2.25 HEX HD, STL, GR 8, Y ZN PL 2
132-0014-000 NUT-HEX, .375-24, GRD 8, Y ZN PL 2
350-0040-000 TAPE, VINYL, FOAM, 1/4", CLOSED CELL, FT .22
350-0041-000 TAPE, FILAMENT, 2.36” – 3” WIDE, FT .22
Optional items:
Part Number Description
1000 DEFLECTION SENSOR TEST DEVICE 1

7
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.
NOTE: A/D refers to the analog-to-digital conversion of the
sensor reading.

8
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. Prepare Axle for welding and bracket placement
1. Clean center of axle in preparation for sensor bracket
placement.
a) Measure and mark center of axle.
b) Clean axle on both sides of the center mark in an
area wide enough to encompass brackets.
1) Use alcohol or degreaser to remove grease.
2) Sand off any paint in the area.
2. If not already assembled, attach alignment tool to the
two brackets
3. Remove foam strip from the bottom of bracket (weld
only).
4. Center bracket on axle
5. Use C-clamps to hold bracket in place.

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.
2. Allow to cool before removing clamps and alignment
tool.
3. Do not operate vehicle with alignment tool in place.

10
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.
GLUE INSTALLATION OVERVIEW DRAWINGS

11
SENSOR INSTALLATION OVERVIEW DRAWINGS
Note: Sensor assembly instructions are the same for
welded or glued bracket installation (the following
diagrams show glued brackets).

12
Alternate Step 2 and 3: Passenger Side Install - Cover.

13
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. Insert blue plunger into glue pack, align
correctly (one side has a larger diameter).
4. Insert nozzle into glue cartridge. Twist to
secure.
5. Insert glue cartridge assembly into caulk gun.
6. Press trigger until glue flows from the nozzle
freely.

14
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. 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).
You must clean the axle with alcohol before you
start sanding and after you finish sanding for glue
installs.

15
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).

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. 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. Assemble the Glue Kit (010-0069-00X) using the
Adhesive Application Kit (010-0021-00X) and the supplied
duo-pak glue cartridge (350-0038-XXX) as per page 13.
Note: See Appendix A page 30 if using Teromix-6700
adhesive.

17
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.
Remove and discard the glue cartridge when finished.

18
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.

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.
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. Ensure the
unfastened side of the alignment tool lifts easily in and out of
the bracket. If it binds, loosen one or both band clamps so
the brackets can be lined up and the alignment tool has free
play.
15. Reset the alignment tool and restore the bolt into the
bracket assembly and loosely fasten with its nut.
16. Remove any excess adhesive in the area around the
brackets, to ensure proper clearance when installing the
cover in the procedure’s final steps.
17. Allow time for the adhesive to cure, according to the
following table:
Ambient Temperature
Fixture Time
32° F (0° C)
6 Hours
54° F (12° C)
3 Hours
72° F (22° C)
2 Hours
Cure time is 24 hours.

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. Apply epoxy paint on glue area and axle
to cover surface where glue bonds to axle and let dry.
20. Clean the bracket channels with (1) of the alcohol pads.
21. Sensor insertion. Clean the sensor ends (010-9089-
000) with the (1) remaining alcohol pad.
22. Insert the sensor with its cable extending away from the
side of the vehicle where you’ll route the sensor extension
cable to the firewall. The “TOP” lettering at the opposite end
should face up. (See Step 2 on page 8 in the Installation
Overview Drawings, showing an installation with routing
planned on the driver side; or Alternate Step 2 on page 9 in
the Installation Overview Drawings showing an installation
with routing planned on the passenger side.)
Figure 10