Vishay Precision Group VPG On-Board Weighing SI Onboard TruckWeigh Use and care manual

TruckWeigh™ Installation,
Setup and Calibration Manual
SI Onboard
A Brand of VPG On-Board Weighing
Part Number 6190236 Revision 1.1

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SI Onboard TruckWeigh™ Manual
Important Information
IMPORTANT INSTALLATION INFORMATION AND LIABILITY WAIVER
SI Onboard designs and manufactures on-board vehicle weighing equipment.
These installation guidelines are provided solely for the use of trained installers
and represent the correct, safe and recommended method of installation.
They must be followed fully to ensure proper, safe installation. Failure to do so
may result in serious consequences including, but not limited to, failure of the
system to function properly and damage to the weighing equipment that could
jeopardize the stability and safety of the vehicle.
SI Onboard accepts no responsibility or liability for consequences arising
from any improper installation of the weighing equipment including but
not limited to, any misapplication or misinterpretation of the installation
information contained herein.
Strict observance of these guidelines should help to ensure accurate weight
measurement and enable safe operation of the vehicle. Failure of our on-board
vehicle weighing equipment due to poor installation workmanship or incorrectly
installed elements remains solely the responsibility of the installer.
SI Onboard does not accept responsibility for the structural integrity of the
vehicle concerned, for any part thereof, and for its proper, safe operation.
The company also reserves the right to make any amendments and alterations
to this document deemed necessary. You should ensure you have the current
version of this information by contacting SI Onboard prior to performing
installation, such as on our website at www.obwvpg.com

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SI Onboard TruckWeigh™ Manual
Contents
Installation................................................................................................................................................................................... 5
Introduction and Scope......................................................................................................................................................... 6
Introduction................................................................................................................................................................................ 6
Scope................................................................................................................................................................................................. 6
TruckWeigh™ Components.............................................................................................................................................. 7
Tools required................................................................................................................................................................................... 8
Checklist ....................................................................................................................................................................................... 8
Typical System Schematics.............................................................................................................................................. 9
Installation of Junction Box for TruckWeigh™ Axle Transducers ................................... 10
Installation of Air Transducer Interface Box ............................................................................................. 10
Installation of Air Pressure Transducer .......................................................................................................... 11
Steel Axle Transducer Installation ........................................................................................................................ 12
Positioning of Transducers on Front Strut Type Suspension .............................................. 13
Positioning of Steel Axle Transducers on Front Leaf Springs............................................... 13
Positioning of Transducers on Rear Single Axle Leaf Springs............................................. 14
Positioning of Transducers on Rear Steel Spring Bogie (Tandem Axle).................... 15
Positioning of Transducers on Rear Hendrickson Rubber Bogie ..................................... 15
Axle Transducer Mounting ............................................................................................................................................ 16
Points to consider .......................................................................................................................................................... 16
Connect the Transducers to the Junction Box ...................................................................................... 17
Install the Chassis and Cab Cabling................................................................................................................... 18
Securing Excess Cable....................................................................................................................................................... 18
Optional Jumper Settings................................................................................................................................................ 19
Power ON Jumper – JP1........................................................................................................................................... 19
Serial Power On Pin 9........................................................................................................................................................... 19
Serial Power On Pin 9 – JP2................................................................................................................................. 19
Install the Meter in the Cab .......................................................................................................................................... 20
Installing the Meter......................................................................................................................................................... 20
Install Truck to Trailer Cable – Truck Side .................................................................................................... 22
Install Truck to Trailer Cable – Trailer Side .................................................................................................. 22
Install 511 Transmitter (Optional)............................................................................................................................ 22
Install Printer (Optional)..................................................................................................................................................... 22

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SI Onboard TruckWeigh™ Manual
Contents
Setup................................................................................................................................................................................................... 23
Introduction and Scope...................................................................................................................................................... 24
Introduction............................................................................................................................................................................. 24
Scope.............................................................................................................................................................................................. 24
Front Panel Functionality ................................................................................................................................................. 25
Power Up the Meter for the First Time............................................................................................................. 26
Entering the Setup Menu.................................................................................................................................................. 26
Changing a Parameter Value ....................................................................................................................................... 26
How to change a parameter value........................................................................................................................ 26
Obtain the Truck’s GVWR and Axle Ratings............................................................................................... 27
Junction Box Configuration - Overview.......................................................................................................... 27
Junction Box Configuration – Examples........................................................................................................ 28
Junction Box Configuration ......................................................................................................................................... 28
Set the Number of Axles and Check the Weigh Mode................................................................... 29
Set the Meter’s Time and Date .................................................................................................................................. 29
Set the Overload Alarm Set Points ....................................................................................................................... 29
Set the Slope Compensation....................................................................................................................................... 30
Configure Tandem Axle (Bogie) Mode............................................................................................................... 31
Tag Axle – Overview................................................................................................................................................................ 32
Configure Tag Axle – if Required............................................................................................................................. 34
Configure Optional 511 Transmitter..................................................................................................................... 34
Configure Optional Printer.............................................................................................................................................. 35
Record the Firmware Versions and Other Details............................................................................... 35
Set the Manager and User PINs............................................................................................................................... 35
Calibration................................................................................................................................................................................ 37
TruckWeigh™ Calibration Process....................................................................................................................... 38
Prerequisites .......................................................................................................................................................................... 38
Weighing the Vehicle..................................................................................................................................................... 38
Procedure .................................................................................................................................................................................. 39
Appendices............................................................................................................................................................................. 43
Junction Box Configuration Diagrams............................................................................................................. 44
4x2 Rigid Chassis...................................................................................................................................................................... 44
6x4 Rigid Chassis...................................................................................................................................................................... 45
8x4 Rigid Chassis...................................................................................................................................................................... 46
4x2 Rigid Chassis...................................................................................................................................................................... 47
4x2 Tractor/Trailer..................................................................................................................................................................... 48
6x4 Tractor/Trailer..................................................................................................................................................................... 49
4x2 Tractor/Trailer..................................................................................................................................................................... 50
Summary of Settings/Parameters ......................................................................................................................... 51
Parts list ............................................................................................................................................................................................... 57

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Installation
SI Onboard
Installation
SI Onboard TruckWeigh™ Manual
Installation

6
SI Onboard TruckWeigh™ Manual
Installation
Introduction and Scope
Please read this installation guide completely before starting the installation so that
all areas are fully understood.
Introduction
TruckWeigh™ is a vehicle payload optimization, overload monitoring and load distribution
system for use on vehicles with steel spring or air suspension or a combination of the two.
Scope
This document is intended as a guide to the installation of TruckWeigh™.
It is only concerned with the two currently supported transducer types for use in a
TruckWeigh™ system:
• TruckWeigh™ axle transducers that measure
suspension deection for use on mechanically
spring suspension systems.
• Air pressure transducers for use on air
suspension systems.
In order to support known chassis types, various system options can be congured using
either of the above transducers or certain combinations of the two.
Any display screenshots used in this document are intended as an illustration of the menu
function being described; as such any specic detail or settings shown will differ from one
installation to another.
Attention:
The TruckWeigh™ indicator has a certain amount of legacy functionality available
through its menu structure which is not considered to be a part of the TruckWeigh™
program, hence is not supported and falls outside the scope of this guide.
Important Notes:
To ensure a reliable and properly functioning system particular importance should be
paid to the following:
• TruckWeigh™ axle transducer installation and conguration – suitable location and
orientation for the transducer should be carefully identied and that location should
then be prepared for the transducer to be attached.
• Slope compensation should also be recorded correctly.
These are covered in detail in this installation guide.

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Installation
SI Onboard TruckWeigh™ Manual
TruckWeigh™ Components
Before starting the installation check that you have the correct
kit of parts for the truck. See Appendix C for a full parts list
including part numbers.
Air suspension groups
will use an air transducer
and interface unit for each
group. An air group can be
1 or more axles connected
to the same air circuit.
Single Air Transducer and Interface
Fig 1.04
Where pressure is
controlled independently
on left and right hand sides
a dual air transducer unit
must be used.
Dual Air Transducer and Interface
Fig 1.05
There is only one meter per
system; this is where the
weights are calculated.
The meter is used for all
display, setup, calibration
and diagnostic functions.
TruckWeigh™ Meter
Fig 1.06
The power cable is used to
connect the meter to the
truck power. There is one
per meter.
Power Cable
Fig 1.07
The signal cable connects
the meter to one or more
junction boxes. There
is one signal cable per
junction box.
Signal Cable
Fig 1.08
Each steel suspension axle
uses a pair of TruckWeigh™
axle transducers.
For example:
• 4x2 all steel suspension
would require 4 axle
transducers.
• 6x4 all steel suspension
would require 6 axle
transducers.
• 8x4 all steel suspension
would require 8 etc.
Axle Transducer
Fig 1.01
The axle transducers
connect to the meter via
junction boxes.
The 4 way junction box
(used also as 2 way
junction box).
• 1x4 way is used for 1
axle/2 transducers with
unused ports blanked
off with dust covers.
• 1x4 way is also used
for 2 axle/4 transducer
installations.
• 2x4 way is used for
4 axle/8 transducer
installations.
CAN Junction Boxes
Fig 1.02
6-way junction box
• The 6 way junction box
is only used for 3 axle/6
transducer installations.
Fig 1.03

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Please note:
Some optional items are not shown here.
These are:
1. 511 hand held display transmitter
2. Thermal printer
They are shown along with their installation details at the
rear of this section of the guide.
The interlink cables are used
to extend each transducer
cable and connect it to the
junction box. Normally one
cable is used per transducer.
In some cases the axle
transducer may reach the
junction box without the use
of an interlink cable.
Interlink Cable
Fig 1.09
The Signal Y Splitter
cable is used when it is
necessary to connect two
signal cables to the meter,
for example, on an 8x4
where two 4way junction
boxes are used.
Signal Y Splitter
Fig 1.10
This is used only on
articulated vehicles,
one per system.
Truck to Trailer Cable – Truck Part
Fig 1.11
This is used only on
articulated vehicles,
one per system.
Truck to Trailer Cable – Trailer Part
Fig 1.12
✓7⁄16” wrench
✓7⁄16” socket and ratchet wrench
✓1⁄4” wrench (if installing a truck to
trailer cable)
✓1⁄4”socket and ratchet wrench
(if installing a truck to trailer cable)
✓Center punch
✓Air or electric drill
✓1⁄8” drill bit
✓9⁄32” drill bit
✓3⁄16” drill bit (if installing a truck to
trailer cable)
✓Wire cutters
✓Red, yellow and blue crimping tool
✓Wire strippers
✓Clamps (to apply pressure to the axle
transducers during installation)
Tools required
Checklist
SI Onboard TruckWeigh™ Manual
Installation

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Typical System Schematics
The above diagrams are examples only and show how
systems on rigid and articulated vehicles might look.
Leaf
Spring
Air
Spring
Air
Spring
Air
Spring
Leaf
Spring
Leaf
Spring
TruckWeigh
Indicator
CAN Air Pressure
Junction Box
and
Transducers
Suspension
Air Bags
CAN Junction Box
and
Axle Transducers
TruckWeigh
Truck Air
System
Truck Air
System
Leaf
Spring
Air
Spring
Air
Spring
Air
Spring
Leaf
Spring
Leaf
Spring
TruckWeigh
Indicator
CAN Air Pressure
Junction Box
and
Transducers
Suspension
Air Bags
CAN Junction Box
and
Axle Transducers
TruckWeigh
Truck Air
System
Truck Air
System
TruckWeigh Kit Number
WKTW10005
CAN Junction Box
and
Axle Transducers
TruckWeigh
Indicator
TruckWeigh
Leaf
Spring
Leaf
Spring
TruckWeigh Kit Number
WKTW10005
CAN Junction Box
and
Axle Transducers
TruckWeigh
Indicator
TruckWeigh
Leaf
Spring
Leaf
Spring
Fig 1.13
Fig 1.14
Installation
SI Onboard TruckWeigh™ Manual

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Installation of Air
Transducer Interface Box
For trucks and trailers with air suspension, install one or more
air transducer interface boxes.
Identify a suitable location for each junction box:
• Each junction box needs to be located close enough to the
transducer positions for the cables to reach it.
• Choose a position that is protected and easy to access.
The air transducer interface box is mounted using 4 x 1⁄4” x 1”
screws and Nyloc nuts. Depending on where it is mounted,
different length screws may be required.
If desired, drill 2 or 4 pilot holes with a 1⁄8” drill.
Drill 4 x 9⁄32” holes in an appropriate location and mount the air
transducer interface box in a similar way to that shown in the
photo above.
The air transducer interface box can be mounted in any
orientation, ideally the cable glands to the air pressure
transducers should point downwards.
Installation of Junction Box
for TruckWeigh™
Axle Transducers
For trucks with mechanical suspension, install one or more
junction boxes.
Identify a suitable location for the junction box:
• Each junction box needs to be located close enough to the
transducers so the cables reach it.
• Each junction box must be mounted on a vertical surface
of the chassis or sub frame with the ‘UP’ arrow pointing
straight up and the ‘FORWARD’ arrow pointing towards
the front of the truck.
• Select a location that is relatively protected and easy
to access.
Fig. 1.15 is shown as an example only. It may be desirable to
mount the junction box to the chassis via a separate mounting
plate that picks up existing chassis holes. The junction boxes
are mounted using 2 or 4 x ¼” x 1” screws and Nyloc nuts.
Socket cap head or Phillips head machine screws should be
used, do not use hex head bolts. Depending on where it is
mounted, different length screws may be required.
Fig 1.15
Fig 1.16
SI Onboard TruckWeigh™ Manual
Installation