LoadMaxx Trailer Scale Installation Guide - Air- · PDF fileLoadMaxx Trailer Scale...

LoadMaxx Trailer Scale

Installation Guide

PN:901-0130-001 R2

On-Board Truck and Trailer Scales

2

Contents

LoadMaxx Overview........................................................................1 Table1:LoadMaxxTrailerSpecifications...........................................2

InstallationOverview.............................................................................3

Tools Required........................................................................4

Mounting the Scale..........................................................................5 MountingFlushtotheTrailer................................................................5

MountingWithaVanBracket...............................................................7

MountingWithaFrameRailBracket...................................................8

Installing Air Sensors......................................................................9Routing Cables...............................................................................11 RoutingtheSensorCableforaSingleSensor................................11

RoutingSensorCablesforTwoSensors..........................................13

RoutingSensorCablesforaFullTrailer............................................14

Connecting Power to the Scale....................................................15 ConnectingPowerwiththeABSConnector.....................................15

ConnectingPowertotheJunctionBox.............................................17

Installing an Alarm.........................................................................18Checking for Correct Installation................................................19 A/DReadingsandSignificance.........................................................19

Limited Warranty...........................................................................20Procedure For Warranty Claims..................................................21

1

Section 1LoadMaxx Overview

LoadMaxxTrailerisaweighingsystemforsemitrailersandfulltrailers.Thescaleworksusingsensorsthatmeasureairpressurechangesinthetrailer’ssuspension;itthenconvertsthosenumbersintoweight.TheweightisdisplayedontheLoadMaxxtrailerdisplay.LoadMaxxdisplaysweightperaxlegroup.Weightsareaccuratetowithin300pounds(140kilograms)andaredisplayedin20-poundor20-kilogramincrements.

IfyouareusingLoadMaxxTrailerinconjunctionwithaLoadMaxxTractorscale,thetrailerweightswillalsodisplayinthetruckcab.DataistransmittedthroughtheexistingJ560cable,soyouwillnotneedtoinstallaspecialtractor/trailerconnection.Youcanalsousetractorandtrailerscaleswithdrop-and-hooksetups.

ThisinstallationguideprovidesinstallationinformationforthreeLoadMaxxtrailerscalemodelnumberslistedasfollows.Ifyouareusingalesscosuchasthepayloadtrailerscale,shouldcontactSupportforfurtherinformation.

5802-Semitrailerwithasingleheightcontrolvalve

5804-Semitrailerwithdualheightcontrolvalves

5882-Fulltrailerwithtwoaxlegroups

Note: After installing your trailer scale, you must calibrate the scale before it will display accurate weights. Please see the LoadMaxx Trailer User Guide and our informational calibration videos, both available on our website, for more information.

LoadMaxx Overview

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LoadMaxx Overview

Table 1: LoadMaxx Trailer SpecificationsAttribute LoadMaxx Specification

Width 6.4inches(162.56mm)Height 3.9inches(99.06mm)Depth 1.9inches(48.26mm)

1.5inches(38.1mm)notincludingDeuschconnector(forflushmountedapplications

Weight .85pounds(.386kg)Temperaturerange -40° to 185° F (-40° to 85° C)Inpultvoltagerange 9.5to32VDCAlarmcircuitcurrentlimit 1.0ampsEnvironmentalspecs Weatherized(immersionto

IP67)formountinginexteriorlocations

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Installation Overview

TherearethreecomponentsoftheLoadMaxxscalethatyouwillinstall:

• Scaleandmountingbracket(unlessflushmounted)

• Airsensor(s)

• Sensorandpowercables

SeeFig.1foranillustrationoftheinstallationoverview.

ForafulllistofpartsinyourLoadMaxxscalekit,seethePartsListincludedinyourkit.

Installation Overview | Tools Required

Fig. 1 Installation Overview

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Tools RequiredYouwillneedthefollowingtoolstoinstallthescaleandsensor.

• Standardwrenchsetoradjustablewrench

• Drillwith1/4-inchdrillbit

• Holesawfor15/8-inchdrillbit(neededonlywhenscaleisflushmounted)

• Flushwirecutter

• Teflonpipethreadtape

Installation Overview | Tools Required Mounting the Scale | Mounting Flush to Trailer

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Section 2Mounting the Scale

Therearethreewaysyoucanmountthetrailerscale:flushmountedtothetrailerframeitself,usingavanbracket,andusingaframerailbracket.Theyareeachdescribedbelow.Choosethemountingmethodthatwillworkthebestwithyourtrailerconfiguration.Mountthetrailerscaleinapositionthatiseasytoviewwhileyouareloadingyourtrailer,andprotectedfromdirecttiresprayandroaddebris.Inregionswheresevereweatherisaconsideration,contactAir-Weighformoreinformationonprotectiveenclosures.

Note: Do not place strain the interface cable leading from the scale connector. A sharp bend in the cable could cause the environmental seal to fail.

Mounting Flush to the TrailerAflushmountedscaleismounteddirectlytothesideofthetrailer(Fig.2).

1. Determinethebestlocationtomountthescale.Thisshouldbeaflatareaofthetrailer,thinenoughtomakedrillingpossibleandaccessiblefrombothfrontandback.Makesurethebacksideofthelocationisfreeofobstaclesanddebristhatwouldinterferewiththeinstallation.

2. Cleanthemountingsurfaceusingisopropylalcoholswabs,providedwithyourhardwarekit.

3. Measuretotheexactcenterbetweenthemountingholes.Thisiswherecableconnectionswillemergefromthescale.Usingtheholesaw,drilla15/8-inchholethroughthetrailersurface.

Mounting the Scale | Mounting Flush to Trailer

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4. Holdthescaleinthelocationyouwillmountit.Markthetrailersurfacethatisvisiblethroughtheholesoneithersideoftheplasticcasingusingapermanentmarker.

5. Usingthemarkedareasasaguide,drilltwo1/4-inchholesintothesurfaceofthetrailer.

6. Feedtheinterfacecablethroughthelargerholeyoudrilledinthetrailer.Plugitintothebackofthescale.

7. Placethescaleoverthespaceyouhavepreparedonthetrailer,makingsurethetwoholeslineupwiththeholesoneithersideofthescalecasing.Usetheprovidedbolts,nutsandwasherstosecurethescaletothesideofthetrailer(Fig.2).

Mounting the Scale | Mounting Flush to Trailer

Fig. 2 Mounting Flush to the Trailer

Mounting the Scale | Mounting with Van Bracket

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Mounting the Scale | Mounting with Van Bracket

Mounting With a Van BracketAvanbracket(Fig.3)isusedprimarilytomounttheLoadMaxxtrailerscaletovanorrefrigeratedtrailers.However,youcanusethisbracketforanysurface-mountedinstallation

1. Determinethebestlocationtomountthescale.Thebracketscrewsshouldbemountedonaledge,andthescaleitselfshouldhangofftheledgewithnoobstaclesblockingit.

2. Holdthebracketinthelocationyouwillmountit.Markthetrailersurfacethatisvisiblethroughtheholesinthetopofthebracketusingapermanentmarker.

3. Usingthemarkedareasasaguide,drillthree1/4-inchholesintothesurfaceofthetrailer.

4. Feedtheinterfacecablethroughtheholeinthebackofthebracketandplugitintothebackofthescale.

5. Securethescaletothebracket.Insertoneboltthrougheachoftheholesinthetrailercasing.Secureinbackusingthesuppliednut.

6. Securethebrackettothetrailersurface.Insertaboltthrougheachoftheholesinthebracketandthroughtheholesyoudrilledinthetrailersurface.Secureinbackusinganut.

Fig. 3 Mounting with a Van Bracket

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Mounting With a Frame Rail Bracket Aframerailbracket(Fig.4)isusedprimarilytomounttheLoadMaxxtrailerscaletolowboyorflatbed-styletrailers.However,youcanusethisbracketonanytrailerframerail.

1. Determinethebestlocationtomountthescaleontheframerail.Thelocationshouldbeeasilyvisiblewhileloadingandprotectedfromdirecttirespray.

2. Holdthebracketinthelocationyouwillmountit.Markthesurfaceoftheframerailthatisvisiblethroughthefourholesinthesidesofthebracketusingapermanentmarker.

3. Usingthemarkedareasasaguide,drillfour1/4-inchholesintothesurfaceoftheframerail.

4. Securethescaletothebracket.Threadonescrewthrougheachoftheholesinthetrailercasing.Secureinbackusingawasher.

5. Feedtheinterfacecabletothebackofthebracketandplugitintothebackofthescale.

6. Securethebrackettotheframerail.Insertoneboltthrougheachoftheholesinthebracketandthroughtheholesyoudrilledintheframerail.Secureinbackusingthesuppliednut(Fig.4).

Mounting the Scale | Mounting with Frame Rail Bracket

Fig. 4 Mounting with a Frame Rail Bracket

Installing Air Sensors

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Section 3Installing Air Sensors

Note: Avoid dropping sensors. Dropping can cause the sensors to fail immediately or shorten their lifespan.

1. Beforeyoubegininstallingairsensors,determineifyouwillneedtoinstalloneortwoairsensors.ForaLoadMaxxscalemodel5802,youwillinstallonlyonesensor.Model5804hasdualheightcontrolvalves,soyouwillinstalltwosensors.Model5882isusedwithafulltrailer,soyouwillinstalltwosensors,oneoneachaxlegroup.Ifyouareunsurehowmanysensorsyouareinstalling,checkthenumberofheightcontrolvalvesonyourtrailer-youwillinstallonesensorpervalve.

2. Locatetheheightcontrolvalveorvalvesonyourtrailer(Fig.5).

3. Followtheairlinefromtheheightcontrolvalvetothetopoftheairbag.Theairsensorwillbeinstalledhere.


Fig. 5 Locating the Height Control Valve

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4. Detachtheairlineconnectionfromthetopoftheairbag.

5. InsertthebrassTfittingprovidedinyourtrailerkitintothetopoftheairbag.Tightenassecurelyaspossible.

6. InserttheairlineintothetopoftheTfitting.

7. ConnecttheairlinefittingtothesideofthebrassTfitting.Tightenassecurelyaspossible.

8. Inserttheairsensorintotheairlinefitting.Pushuntilthesensorsitssecurely.Pulllightlyonthesensortotestforafirmconnection.SeeFig.6foradiagramoftheTfittingandsensorsetup.


Fig. 6 Fitting and Air Sensor Setup

Routing Cables | Routing Sensor Cable for Single Sensor

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Section 4Routing Cables

DependingonwhetheryouareinstallingLoadMaxxonatrailerwithasingleheightcontrolvalve,adualheightcontrolvalve,oronafulltrailer,theprocessofroutingsensorcableswilldifferslightly.Followtheinstructionsintheapplicablesection.

Note: If your trailer has a sliding suspension, route all cables with the existing wiring harness. Improper routing could damage cables when the slider is moved.

Routing the Sensor Cable for a Single SensorTheseinstructionsareformodelnumber5802.

1. Findthesensorcableprovidedinyourscalekitandconnectoneendtotheendoftheairsensoryouinstalledearlier.

2. Routethecablealongtheaxleandtheframeofthetrailertowardthelocationyouchoseearlierforthescale.Leaveenoughlengthtoconnectthesensorcabletotheinterfacecable.Ifatallpossible,routealonganexistingwiringharness.Becarefultoavoidroutingalongpiecesoftheframethatmaymoveorcausewiringtorub.

3. Securethecablelooselytotheframeusingnylonties.

4. Connecttheendofthesensorcabletothethree-pinconnectorontheinterfacecable(Fig.7).Makesureallcablesareundernostrainandarenotbent.

5. Tightenandtrimallnylonties.


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Fig. 7 interface Cable for Single Sensor

Routing Cables | Routing Sensor Cables for Two Sensors

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Routing Sensor Cables for Two SensorsTheseinstructionsareformodelnumber5804.

1. Findthetwosensorcablesprovidedinyourscalekit.Connecteachtotheairsensorsyouinstalledearlier.

2. Routethetwocablesalongtheaxleandtheframeofthetrailertowardthelocationyouchoseearlierforthescale.Leaveenoughlengthtoconnectthesensorcabletotheinterfacecable.Ifatallpossible,routealonganexistingwiringharness.Becarefultoavoidroutingalongpiecesoftheframethatmaymoveorcausewiringtorub.

3. Securethecableslooselytotheframeusingnylonties

4. Connecttheendofthesensorcablestothetwothree-pinconnectorsontheinterfacecable(Fig.8).Withmodel5804,itdoesnotmatterwhichsensorcableyouconnecttowhichport.Makesureallcablesareundernostrainandarenotbent.


Routing Cables | Routing Sensor Cables for Two Sensors

Fig. 8 interface Cable for Two Sensors

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Routing Sensor Cables for a Full TrailerTheseinstructionsareformodelnumber5882.

1. Findthetwosensorcablesprovidedinyourscalekit.Connectsensorcabletoeachtotheairsensorsyouinstalledearlier.

2. Routethetwocablesalongtheaxleandtheframeofthetrailertowardthelocationyouchoseearlierforthescale.Leaveenoughlengthtoconnectthesensorcabletotheinterfacecable.Ifatallpossible,routealonganexistingwiringharness.Becarefultoavoidroutingalongpiecesoftheframethatmaymoveorcausewiringtorub.

3. Securethecableslooselytotheframeusingnylonties.

4. Connecttheendofthesensorcablestothetwothree-pinconnectorsontheinterfacecable.ConnectthesensorcableforthefrontaxlegrouptoSensorA,andthesensorcablefortherearaxlegrouptoSensorB.


Routing Cables | Routing Sensor Cables for Full Trailer Connecting Power to Scale | ABS Connector

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Section 5Connecting Power to the Scale

YoucanconnecttheLoadMaxxtrailerscaletothetrailer’spowersourceeitherthroughtheABSbrakesystemordirectlythroughthepowerjunctionbox.Bothmethodsareequallyeffectiveregardlessofyourtrailersetup;choosethemethodthatismostconvenient.

Connecting Power with the ABS ConnectorNorthAmericantrailermanufacturersuseoneoftwostandardconnectorstoconnecttheABSbrakesystemtothetrailer’swiringharness:USA,whichusesa6-pinplug,orSealco,whichusesa5-pinplug.Air-WeighprovidesT-breakoutconnectorsthatdonotrequiresplicingorsolderinganddonotinterruptpowertotheABSsystemforeachoftheseconnectortypes.WhenyouorderyourLoadMaxxtrailerkityouwillspecifywhichtypeofconnectoryourtruckuses.

1. LocatetheABSwiringsystem.Tracethepowercabletoitsconnectiontothetrailerwiringharness.

2. Disconnectthe5-or6-pinconnectionbetweentheABSpowercableandthetrailerwiringharness.

3. ConnecttheABSpowercableandtrailerwiringharnesstoeitherendoftheT-breakoutconnectorprovidedwithyourLoadMaxxtrailerkit.Makesurethelockingtabsarelockedsecurely.IfyouareusingtheUSAconnector,makesureallpinsareproperlyalignedandthewhiteplugisfirmlyseatedinitslockinghole(Fig.9).FailuretodosowillcausefaultsinyourABSsystem.

Connecting Power to Scale | ABS Connector

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4. Connectthescale’spowercabletotheT-breakoutconnector(Fig.10).

5. Routethescale’spowercablealongtheframeofthetrailertowardthelocationwherethescaleisinstalled.Ifpossible,routealonganexistingwiringharness.Ifthetrailerhasaslidingsuspensionyoumust useanexistingwiringharnesstoavoiddamagingorbreakingthecable.

6. Securethecablelooselytotheframeusingnylonties.

7. Connecttheendofthepowercabletothepowerconnectionontheinterfacecable(seeFig.8).Makesurethecableisundernostrainandisnotbent;leaveextracablelengthifroutingonatrailerwithaslidingsuspension.


Connecting Power to Scale | ABS Connector

Fig. 10 Connecting the T-Breakout to the Power Cable

Fig. 9 Locking Pin

Connecting Power to Scale | Junction Box

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Connecting Power to the Junction BoxIfyouplantoconnectyourtrailerpowerthroughthejunctionbox,orderthekitwithabluntcutpowercable(Fig.9).Or,ifyouorderedacablewithaconnector,youcanusewirecutterstocutofftheconnectorbeforeconnectingtothejunctionbox.

1. Tracethetrailerwiringharnesstowhereitconnectstoajunctionbox.Removethecoverofthejunctionboxtoexposethewiring.

2. Identifythepowersourceyouwanttouse.WerecommendtheABSpowerwire,whichisusuallyblue.IfthereisnoABSpowerwireintheboxorifitisnotavailable,youcanconnectthescale’spowerwiretothemarkerlightpowerwire,whichisusuallybrownorblack.Werecommendagainstusingthemarkerlights,however,astheLoadMaxxscalewillnotturnonwhenthemarkerlightsareoffifyouusethemtopowerthescale.

3. Testthewireusingatestlighttomakesurepowerispresent.

4. Connectthebluepowerwireontheendofthetrailerscalepowercabletothepowersourceyouhavechosen.Securewithelectricaltape(Fig.11).

5. Connectthewhitegroundwireontheendofthepowercabletothegroundwireinthejunctionbox,whichisusuallywhite.Securewithelectricaltape(Fig.11).

Connecting Power to Scale | Junction Box

Fig. 11 Connecting Power Using a Blunt Cut Power Cable

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Section 6Installing an Alarm

Thepowerinterfacecableprovidedinyourscalekitincludesapowersourceforinstallinganalarm,whichcanbealightoranoise-producingdevice.Toinstallanalarm,followthestepsbelow.

1. Provideanyself-groundedalarmwithacurrentdrawof1.0ampsorless.(Youmustinstallarelayforanyalarmthatdrawsmorethan1.0amps.)

2. Mountthealarminthelocationyouwouldlikeonthetrailerbody.

3. Routethealarm’spowercablealongthebodyofthetrailertothetrailerinterfacecableconnectedtothebackofthescale.

4. Locatethealarmpowerwire(Figs.7and8).Thewireisgrayandsealedontheendwithaplasticcover.

5. Cutofftheplasticcoversothewireisexposed.

6. Connectthewiretothepowercableofthealarmyouprovide.Securewithelectricaltape.

PleaseseetheUserGuide,availableonourwebsiteorfromourSupportteam,forinstructionsoncalibratingyourscale.Yourscalemustbecalibratedbeforeitwilldisplaycorrectweights.

Installing an Alarm Checking for Correct Installation

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Section 6Checking for Correct Installation

AfteryoufinishinstallingyourLoadMaxxscale,followthestepsbelowtomakesureyouhaveinstalledthescalecorrectly.Thiswillpreventtheenduserfromrunningintoissueswhenusingthescale.

1. Fromthemainmenu,press▼untilthescreenreadsDIAGNOSE.PressENTER.

2. Press▼untilthescreenreadsATODO.PressEnter.Thescreenshouldread“A/D”andshowanumber.ThatnumberisyourA/Dreading.UsethetablebelowtodetermineifyourA/Dreadingisappropriate.

3. Fromyourtractorcab,emptytheheightcontrolvalveonyourtrailerandrefillit.Wait15to30secondsandchecktheA/Dreadingonyourtraileragain.

4. RepeatStep3aboveagain.

5. IftheA/Dreadingsareappropriateinallthreereadings,yourtrailerhasbeeninstalledcorrectly.Iftheyareinaccurate,checkallconnectionsandmakesuretheyaresecurelyattached.Thenchecktheheightcontrolvalvetoseeifitislooseorbroken,whichcancauseinaccurateweightreadings.

6. A/D Readings and Significance

A/D Reading Should Reflect409 airbagdeflated,noweight-

equivalentto0pounds570to1200 appropriateforanempty

trailer1400to2100 appropriateforatrailer

loadedtofullcapacity

Checking for Correct Installation

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Limited WarrantyForproductfailuresduetomaterialormanufacturingdefects,Air-Weighwillreplaceorrepairallcomponentsforuptothreeyearsfromshipmentdatetotheend-userAir-Weighcustomer.Thesethree-yearcomponentsinclude:displays,ComLinks,sensors,powercables,sensorassemblies,sensorharnesses,andallotherassociatedexternalcomponents.Air-Weighassumesnoresponsibilityforadministeringwarrantyclaimsdirectlywithanythird-partyendusers.

TheresponsibilityofAir-Weighunderthiswarrantyislimitedtotherepair,replacement,orcreditofthedefectivepartorassembly.

Thiswarrantydoesnotcoverincidentalorconsequentialdamagetopersonsorpropertycausedbyuse,abuse,misuse,orfailuretocomplywithinstallationoroperatinginstructions.Thislimitedwarrantydoesnotapplytoanyproductthathasfailedduetoaccident,abuse,alteration,installationnotconsistentwithprintedinstallationinstructions,impropermaintenance,orimproperoperationorasaresultofsystemintegrationorinstallationnotexplicitlyapprovedinwritingbyAir-Weigh.

Air-WeighanditsresellersshallhavenoresponsibilityorliabilityfordamagesifthepurchaseroranyotherpersonaltersthevehicleincorporatingAir-Weighproducts.ThislimitedwarrantyshallnotapplytoanyproductthathasbeenrepairedoralteredbyanyonenotemployedbyAir-Weighornotoperatedinaccordancewiththemanufacturer’sprintedmaterialdeliveredwiththisproduct.

Air-Weighherebyexpresslydisclaimsanyandallimpliedwarrantiesofanytype,kind,ornaturewhatsoever,andparticularlyanyimpliedwarrantyofmerchantabilityorfitnessforaparticularpurposenotexpresslystatedbyAir-Weighinitsprintedmaterialdeliveredwithitsproducts.Somestatesdonotallowtheexclusionorlimitationofincidentalorconsequentialdamages.Ifsuchlawsapply,thelimitationsorexclusionscontainedinthetermsandconditionsofthiswarrantymaynotapply.Thiswarrantygivesyouspecificlegalrights,andyoumayalsohaveotherrightsthatvaryfromstatetostate.

MaybecoveredbyU.S.PatentNos.5478974,5780782,7478001ForeignPatentNos.260494,677998,2122766

Copyright©2004,2006,2007,2010,2014byHi-TechTransportElectronics,Inc.Allrightsreserved.Air-Weigh®,ComLink™,andHi-TechTransportElectronicsaretrademarksorregisteredtrademarksofHi-TechTransportElectronics,Incorporated.Otherbrand,product,orservicenameslistedinthisdocumentarethetrademarksorregisteredtrademarksoftheirrespectiveholders.Informationcontainedinthisliteraturewasaccurateattimeofpublication.Productchangesmayhavebeenmadeaftercopyrightdatesthatarenotreflectedinthisdocument.

Limited Warranty

21

Procedure For Warranty ClaimsALLcustomersshouldfirstcontactAir-WeighCustomerSupportDepartmentat(888)459-3247forquestionsregardingtheuse,operation,repairorreturnofanyAir-Weighproduct.

IntheeventAir-WeighrequeststoexaminetheproductpriortodispositionORforrepairorreplacement,Air-WeighrequiresaReturnMaterialAuthorization(RMA)numberbeissuedbeforetheitemisreturned.CustomerSupportwillissuetheRMAnumber.PleasereferencethisRMAnumberinallcorrespondence.

Claimeditemsshallbeshippedfreightpre-paidto:Air-Weigh CustomerSupportDepartment 1720WillowCreekCircle,Suite510 Eugene,Oregon97402,USA

TheAir-WeighRMAnumbermustappearontheoutsideofthereturnpackaging.Air-Weighshallexaminereturnedmaterialwithin30daysafterreceipt,orsoonerifmutuallyagreedupon.IfAir-Weighdeterminesthatthepartorassemblywasdefectiveinmaterialorworkmanshipandwithinthewarrantyperiod,Air-Weighwillrepairorreplacethepartorassemblyandreturnfreightpre-paid.IntheeventAir-Weighdeterminesthatthepartorassemblycannotberepairedorreplacedandiswithinthewarrantyperiod,acreditnottoexceedthepurchasepricewillbeissuedtotheAir-Weighcustomer.

ForourcustomersusingpurchaseordersAir-Weighwillprocessacreditmemoandnotifythecustomerbyemailorfax.ThecustomerwillprocessacorrespondingdebitmemoandnotifyAir-Weighaccordingly.

IfthepartorassemblyreceivedbyAir-Weighdoesnotmeettherequirementsofthewarrantyprogramsetforthabove,attheAir-Weighcustomer’srequestthepartorassemblywilleitherbediscarded,returnedfreightcollect,orrepairedorreplacedattheAir-Weighcustomer’sexpenseandreturnedfreightcollect.

Procedure for Warranty Claims

1730WillowCreekCircle•Eugene,OR97402-9152USAP.O.Box24308•Eugene,OR97402-0437USA

Telephone(541)343-7884•OrderDesk(888)459-3444CustomerSupport(888)459-3247•Fax(541)431-3121

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