Air Weigh LOADMAXX User manual

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PN 901-0154-000 R0
Air-Weigh Customer Support: 888-459-3247
LoadMaxx
Installation Guide
Ford F-750 Trucks

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Table of
Contents
TABLE OF CONTENTS.................................................................2
ABOUT LOADMAXX FOR F-750...................................................4
ABOUT INSTALLATION................................................................5
Overview.............................................................................5
Installation Components...................................................... 5
TOOLS REQUIRED .......................................................................6
Optional Tools.................................................................. 6
INSTALLING THE STEER AXLE SENSOR BRACKET..................7
Preparing the Steer Axle Sensor Brackets........................... 7
Welding the Bracket ............................................................ 9
Adding a Protective Spray Paint Coating........................... 10
INSTALLING THE DRIVE AXLE SENSOR ..................................11
Assembling the Bracket to the Jig...................................... 11
Surface Preparation........................................................... 12
Welding the Bracket .......................................................... 13
Installing the Deflection Sensor ......................................... 14
INSTALLING THE COMLINK AND DISPLAY ..............................16
Preparing the Cab Display for Installation.......................... 16
Installing the Cab Display.................................................. 16
Mounting the ComLink....................................................... 17
Connecting Cables............................................................ 18
Table 2: Wiring Harness Hookup.................................... 18
Routing Cables.................................................................. 19
Securing Cables and Reassembling the Dash................... 19
INSTALLING AND ADJUSTING THE STEER AXLE SENSOR ....20

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Installing the Deflection Sensor ......................................... 20
Setting the A/D Values ...................................................... 22
A/D Reading is BELOW 750........................................... 22
A/D Reading is ABOVE 1250.......................................... 23
Final Sensor Torque....................................................... 23
Steer Axle Finishing Touches............................................ 23
TESTING AND ADJUSTING THE DRIVE AXLE SENSORS.........26
A/D Reading is BELOW 750........................................... 27
A/D Reading is ABOVE 1250.......................................... 28
Final Sensor Torque....................................................... 28
LIMITED WARRANTY ................................................................. 30
PROCEDURE FOR WARRANTY CLAIMS...................................31

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About LoadMaxx for F-750s
LoadMaxx is a weighing system for vehicles that works by using
deflection sensors and/or air pressure sensors. The sensors
measure suspension flex or air pressure changes and convert
that number into weight which is displayed in the truck cab..
Weight information, which includes axle group weights as well as
net and gross vehicle weights, are also displayed
The LoadMaxx scale includes a dash-mounted display, a
ComLink™ module, mounting cables, a deflection sensor with
mounting hardware for the steer axle, and a deflection sensor
with mounting hardware.
Please see the User Guide, included with your scale kit, to
calibrate your scale after installation.
Fig. 1: Major Components Location

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About Installation
Overview
There are three major components of the LoadMaxx scale that
you will install:
•Electronics: dash-mounted display, ComLink module,
power cables and sensor extension cables
•Deflection sensor for the steer axle (vocational vehicles only)
•Deflection sensors for the suspension
Installation Components
For a full list of installation components, please see the Bill of
Materials, insert 905-0008-000 R0.

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Tools Required
You will need the following tools to install the deflection sensors
on the steer and drive axles.
•Sander/grinder
•40-grit medium sandpaper
•Chalk or permanent marker
•Flat-blade screwdriver
•Combination wrench
•Torque wrench
•22mm socket and socket handle
•Enamel spray paint, any color
•Welder, MIG or ARC
•E7018 welding electrodes for ARC welders
•E70S-3 or E71T-1 welding wire for MIG welders
•309 Stainless Wire
•C-clamps
•Tape measure
Optional Tools
•Deflection sensor test box, available from Air-Weigh

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Installing the Steer Axle Sensor
Bracket
Preparing the Steer Axle Sensor Brackets
1. Locate and mark the center of the steer axle (Fig. 2)
Fig. 2: Marking the Center of the Steer Axle
2. Using chalk or permanent marker, mark the top of the steer
axle 3 inches on either side of the center mark (6 inches in
total). Clean this area. If the axle is heavily caked with dirt or
grease, use Brakleen to remove the worst. Then clean the 6-
inch area using two of the alcohol pads supplied in the
installation kit (Fig. 3).
3. Using 40-grit medium sandpaper or a pneumatic grinder,
sand the 6-inch area until nothing remains but bare metal.
We recommend that you partially sand down the mold line as
well. See Fig. 3.
AW5800-1024
Center Mark

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Fig. 3: Cleaning and Sanding the Steer Axle
Fig. 5: Cleaning the Bottom of the Bracket Assembly
4. Clean the underside of the bracket assembly with one of the
supplied isopropyl alcohol pads (Fig. 5).
5. Verify that the bracket contact pads fit 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.
AW5800-1022
Alcohol Pad

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Welding the Bracket
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
(Fig. 3). Use C clamps to hold the bracket in place. Make
sure you leave the alignment tool in the bracket assembly
while welding.
Fig. 3: Bracket assembly centered on axle
2. 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 (Fig. 4). Do NOT weld the
sides of the bracket, only the edges indicated on the next
page. Air-Weigh recommends that you use equipment similar
to Miller Shopmaster 300 AC/DC; AMP/VOLT setting of 22;
wire speed of 3.5; and a welding argon gas mixture of 75/25.
MIG welding should use 309 stainless wire. MIG welding will
use the same settings as the Miller Shopmaster noted above.

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NOTE: Do not operate the vehicle while the alignment tool is
still in place.
Fig. 4: Welded axle and bracket
Adding a Protective Spray Paint Coating
To prevent the steer axle bracket from delaminating due to
corrosion, we recommend you spray paint around the base of
the bracket.
1. Using any enamel-based spray paint, paint around the base
of the bracket and over the glued section. Paint all bare
metal around the bracket completely.
2. Once the paint is dry, we recommend that you paint all
exposed metal a second time.
Fig. 10: Spray Paint Coating