Air Weigh LOADMAXX Installation Manual

Air-Weigh Customer Support: 888-459-3247 LoadMaxx Installation Guide Mack Camelback Suspensions Welded Steer and Drive Brackets

ABOUT LOADMAXX FOR CAMELBACK SUSPENSIONS......................1 ABOUT INSTALLATION.............................................................................1 Overview..........................................................................................1 TOOLS REQUIRED...................................................................................2 Optional Tools................................................................................2 INSTALLING THE STEER AXLE SENSOR BRACKET............................3 Preparing the Steer Axle Sensor Brackets...............................3 Welding the Bracket......................................................................6 Adding a Protective Spray Paint Coating..................................7 INSTALLING THE DRIVE AXLE SENSOR BRACKET.............................8 Preparing the Camelback Suspension......................................8 Welding the Bracket.....................................................................9 Adding a Protective Spray Paint Coating................................10 ROUTING CABLES..................................................................................11 INSTALLING THE COMLINK AND DISPLAY..........................................12 Preparing the Cab Display for Installation...............................12 Installing the Cab Display...........................................................12 Mounting the ComLink...............................................................13 CONNECTING CABLES...........................................................................14 Power and Ground Table....................................................14 Securing Cables and Reassembling the Dash......................14 INSTALLING AND ADJUSTING THE STEER AXLE SENSOR..............15 Installing the Delection Sensor.................................................15 INSTALLING AND ADJUSTING THE DRIVE AXLE SENSOR...............17 Setting A/D Values.....................................................................18 Adjusting the A/D Reading.....................................................19 Final Sensor Torque...................................................................20 COVER INSTALLATION..........................................................................21

Suspensions LoadMaxx is a weighing system for vehicles that works by using delection sensors and/or air pressure sensors. The sensors measure suspension lex or air pressure changes and converts 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 for vehicles with Mack Camelback suspension includes a dash-mounted display, a ComLink™ module, mounting cables, a delection sensor with mounting hardware for the steer axle, and a second delection sensor with mounting hardware for the Camelback suspension. Please see the Calibration and User Manual, included with your scale kit, to calibrate your scale after installation. About Installation Overview There are three major components of the LoadMaxx scale that you will install, listed as follows. • Electronics: dash-mounted display, ComLink module, power cables and sensor extension cables • Delection sensor for the steer axle suspension • Delection sensors for the Camelback drive axle suspension

steer and drive axles. • Sander/grinder • 40-grit medium sandpaper • Chalk or permanent marker • MIG or ARC welder • For ARC welder: E7018 welding electrodes OR • For MIG welder: E70S-3 or E71T-1 welding wire • Two C clamps • Flat-blade screwdriver • Torque wrench, 120 ft-lb • 22mm socket and 5/16-inch socket • Enamel spray paint, any color • Tape measure Optional Tools Delection sensor test box (P/N 1001)

Bracket Preparing the Steer Axle Sensor Brackets 1. Locate and mark the center of the steer axle. 2. Using chalk or a permanent marker, mark the top of the steer axle 3” on either side of the center mark (6” in total). Clean this area. If the axle is heavily caked with dirt or grease, use Brakleen to remove the worst. 3. Using 40-grit medium sandpaper or a pneumatic grinder, sand the 6” area until nothing remains but bare metal. We recommend that you partially sand down the mold line as well. Marking the Center of the Steer Axle

5. Verify that the bracket contact pads it 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. 6. Once you have prepared the axle, place the bracket assembly onto the axle to ensure that it its properly. All four bracket mounting pads should sit irmly on the axle without rocking in any direction. If the bracket rocks, sand or grind off any excess axle material until the bracket its properly. NOTE: Make sure that the main body of the bracket does not touch the axle. Only the feet of the bracket should touch the axle. Sanding the Steer Axle

bracket assembly. Removing the Protective Plastic Strips 8. Clean the underside of the bracket assembly with one of the supplied isopropyl alcohol pads. Cleaning the Bottom of the Bracket Assembly

NOTE: 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. Use C clamps to hold the bracket in place. Make sure you leave the alignment tool in the bracket assembly while welding. 2. Tack weld all 8 corners and then illet weld a full bead on the front and back edges of each bracket piece. Bracket Assembly Centered on Axle Bracket Assembly Centered on Axle NOTE: Make sure that the main body of the bracket does not touch the axle. Only the feet of the bracket should touch the axle. Do not operate the vehicle while the alignment tool is still in place. TACK WELD LOCATIONS

To prevent steer axle 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 welded 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. Spray Paint Coating

Preparing the Camelback Suspension 1. Locate and mark the top center of the trunnion tube. Sanding the Trunnion Tube Marking Center of Trunnion Tube 2. Using chalk or permanent marker, mark the top of the trunnion tube 3-3/8 in. (85.725mm) on both sides of the center mark. The overall measurement is 6-3/4 in. (171.45 mm). 3. Using a grinder or 40-grit medium sandpaper, sand the marked off area until it is free of paint and other residues. 4. Clean the sanded area. 5. Re-mark the center of the trunnion tube.

1. Place the mounting bracket assembly on the top center of the trunnion tube. Mark the center on the alignment tool and ensure it lines up with the center mark on the trunnion tube. 2. Use C clamps to hold the bracket in place. Make sure you leave the alignment tool in the bracket assembly while welding. Placing the Brackets on the Trunnion Tube 3. Tack weld all 8 corners of the base of the bracket. 4. Fillet weld a full bead on the edges of each bracket piece. 5. Allow the weld and the bracket to completely cool. Alignment Tool

1. To prevent the drive axle brackets from delaminating due to corrosion, we recommend you spray paint around the base of the brackets. 2. Using any enamel-based spray paint, paint around the base of the bracket. Paint all bare metal around the bracket completely. 3. Once the paint is dry, we recommend that you paint all exposed metal a second time. Spray Painting the Bracket

extension cable along their respective axles and the frame, and then through the cab irewall. Leave enough length for sensor connections. If at all possible, route along an existing wire harness. Be careful to avoid routing along pieces of the frame that may move or cause wiring to rub. 2. Secure the cables loosely to the suspension using zip ties. NOTE: Keep all cables a minimum of 12” from exhaust piping or properly shield cables.

Preparing the Cab Display for Installation 1. Select a location for the display (1) on the dash panel (5) with at least 3” of clearance behind the dash panel (5) for the unit and its connections. A higher dash position provides better visibility. 2. Using a hole saw, cut a 2-1/8” hole (2) in the dash where you will mount the display. 3. Remove the hex nuts (4) from the studs (6) on the back of the display (1) to release the mounting bracket (3). Installing the Cab Display 1. Position the display (1) in the hole so that it appears level on the dash. 2. Reinstall the mounting bracket (3) on the back of the display (1) and secure with two nuts (4) on the display studs (6). Tighten the nuts (4) and secure the display (1) to the dash using 6 in-lbs. of torque. Do not over- tighten the mounting bracket nuts (4). Display Preperation and Installation

1. Select a location behind the dash for the ComLink module, ensuring there is adequate access to the scale and the electrical connections. 2. The ComLink module should be oriented with the connectors facing downward and installed by either one of the following methods, using the hardware provided: Use zip ties through the holes in the ComLink module mounting ears to secure it to any appropriate wire harness behind the dash. -OR - Find a lat location where the ComLink module can be attached using the 2-sided adhesive tape already in position on the back of the ComLink module. Remove all dust, grease or debris from the lat location using the supplied alcohol pad. Remove one or both of the red strips from the back of the ComLink module, exposing the adhesive tape. Place the ComLink module against the cleaned lat area and push hard enough to ensure adhesion. For best results, push the ComLink module into place using 15 ft lbs of pressure, being careful not to crack the case. Using this method will make the ComLink module more dificult to remove. NOTE: If you are using the optional printer, please see the document Printer Installation Instructions for information on connecting the printer to the ComLink.

vehicle’s electrical system, to the dash display unit, and, if desired, to an alarm output. Power and Ground Table White Wire Vehicle Chassis Ground Blue/Black Wire with In- Line Fuse 12VDC or 24VDC Key Hot Power Gray Wire/Brown Wire Alarm output 1 and 2 (same voltage as vehicle power) Black Wires Alarm ground Return 1 and 2 1. Connect the white wire to chassis ground. 2. Connect blue/black wire with inline fuse to the positive (+) or “hot” side of the 12 VDC or 24 VDC key hot power source. DO NOT connect directly to battery. 3. Connect the 10-pin plug of the power interface cable to the ComLink module. 4. Connect both the 2-pin and the 4-pin plugs of the power interface cable to the display. 5. When using an alarm, connect the alarm output wire and the ground return wire to the desired device (buzzer, horn, light, etc.). Securing Cables and Reassembling the Dash 1. Connect the extension cable to the ComLink module in the dash. Drive cables should be connected to Port A and the steer cable should connect to Port B. 2. Coil and secure any excess wire using zip ties. 3. Tighten all zip ties and trim. 4. Reassemble the dash assembly after all sensors have been installed (next section) and sensor cables are connected. Ensure all connections are tight.

Axle Sensor Installing the Delection Sensor 1. Remove the alignment tool from the brackets. Retain the nuts and bolts. 2. Insert the steer axle sensor with its cable extending toward the side of the vehicle where the sensor extension cable has been routed to the irewall. Make sure the engraved lettering faces up. 3. Align the steer axle sensor with the holes in the steer axle bracket assembly. 4. Insert one bolt through the bracket hole on the sensor end with the engraved lettering on it so that the bolthead is secured in the manufactured bolthead holder. Place a washer and a nut at the end of the bolt and hand-tighten the nut. Inserting the Sensor Into the Bracket

that the bolthead is secured in the manufactured bolthead holder.. Hand-tighten the nut. Attaching the Sensor to the Bracket

Axle Sensor 1. Remove the alignment tool from the brackets. Retain the nuts and bolts. 2. Insert the delection sensor into the brackets with its cable extending toward the side of the vehicle where you’ll route the sensor extension cable to the irewall. The engraved lettering on the sensor should face up. 3. Align the delection sensor with the bracket holes. 4. Slide the bolts through the bracket holes so that the boltheads are secured in the manufactured bolthead holders. Inserting the Sensor Inserting Bolt and Washers into Sensor and Bracket

At this point, you have installed all of the LoadMaxx system components. You will next adjust the steer and drive axle delection sensors to read weight correctly by setting the A/D values. A/D refers to the analog-to-digital conversion of the sensor reading. This step will require the use of either the LoadMaxx in-dash display or the Delection Sensor Test box (P/N 1001). If using the LoadMaxx in-dash display, the scale must be installed and powered, and the Delection Sensor Extension Cable must be installed. The process below must be completed for both the steer and drive axles. 1. To assemble the connectors, insert the delection sensor connector plug into the sensor extension cable connector OR connect to the delection sensor test box. Ensure the locking tabs on the connector plug engage completely. Assembling the Electrical Connector 2. Tighten both nuts and use a torque wrench to torque to 60 ft-lbs. NOTE: When tightening the bolts, ALWAYS torque the nut, NOT the bolt head. The bolt head should be in the bolt head holder, which is built into the bracket.

ignition to power on the display), or the delection sensor test box. If the reading is within range (750-1250), continue to instructions for the Final Sensor Torque. If the reading is not within range, follow the instructions to adjust the A/D readings below. Adjusting the A/D Reading If the A/D reading is above 1250, follow these instructions: 1. Loosen the nuts on both ends of the sensor 2. At the plastic nut where the cable enters the sensor, exert DOWNWARD pressure with your ingers until the A/D reading is between 750 and 1250. Continue to apply pressure to maintain the desired A/D reading during the torque procedures in step 3. 3. Tighten the nut on the cable end of the sensor and torque to 60 ft/lbs. Continue to apply pressure with your inger to the plastic nut during torquing in order to maintain the desired A/D reading. If the A/D readings are still within the 750 to 1250 range after the nuts on both sides of the sensor have been torque to 60 ft/lbs, continue to instructions for the Final Sensor Torque.

follow the steps below: 1. Loosen the nuts on both ends of the sensor 2. At the plastic nut where the cable enters the sensor, exert UPWARD pressure with your ingers until the A/D reading is between 750 and 1250. Continue to apply pressure to maintain the desired A/D reading during the torque procedures in step 3. 3. Tighten the nut on the cable end of the sensor and torqued to 60 ft/lbs. Continue to apply pressure with your inger to the plastic nut during torquing in order to maintain the desired A/D reading. If the A/D readings are still within the 750 to 1250 range after the nuts on both sides of the sensor have been torqued to 60 ft/lbs, continue to instructions for the Final Sensor Torque. Final Sensor Torque 1. Torque both nuts to 120 ft/lbs. 2. Perform a inal check to A/D values using the readings from the in-cab QuickLoad display, not from the A/D Box. If A/D readings are not within range, repeat the Adjusting the A/D reading steps.

1. Mount the cover over the sensor and the brackets so that the sensor cable is completely under the cover. The sensor extension cable should emerge from the cover’s end port on whichever side you choose to route the cable. Ensure that the cable has free play and is not pinched by the sensor cover. 2. Very loosely install band clamps around the steer axle on both ends of the delection sensor cover. Ensure that the band clamp on each side circles both the steer axle and the cover lange. 3 Secure the sensor cable to the axle using zip ties. Run the drive sensor extension cable along the rear of the axle toward either side of the truck, securing with a band clamp. Place split loom over the band clamp where it crosses over the cable. Secure the cable to the band clamp with zip ties. Use additional 24” zip ties as required to secure the cable to the steer axle. Cover with Sensor Extension Cable

1. Locate the opening in the end of the cover. The opening is used for the sensor cable to go through. Cable Opening in Cover 2. Cut a notch in the supplied grommet and place it on the sensor cable. Notching the Grommet

hole with the Molex connector of the sensor cable on the outside of the cover and set the Delection Sensor Cover over the sensor on the trunnion tube. Placing the Cable and Grommet into Cover 4. Slip each band clamp over the lange on the ends of the cover and tighten in place. Your Air-Weigh scale installation is now complete. Clamping the Cover to the Trunnion Tube

replace or repair all components for up to 3 years from shipment date to the end-user Air-Weigh customer. These three-year components include: Displays, ComLinks, Sensors, Power Cables, Sensor Assemblies, Sensor Harnesses, and all other associated external components. 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, and particularly any implied warranty of merchantability or itness 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 speciic legal rights and you may also have other rights, which vary state to state. May be covered by U.S. Patent Nos. 5478974, 5780782, 7478001 Foreign Patent Nos. 260494, 677998, 2122766 Copyright © 2004, 2006, 2007, 2010, 2011, 2012, 2013 by Hi-Tech Transport Electronics, Inc. All rights reserved. Air-Weigh®, ComLink™, and Hi-Tech Transport Electronics are trademarks or 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 dates that are not relected in this document.

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