DUAL LEVELING VALVE PROCESSOR INSTALLATION MANUAL
Contents
1. For repairs or replacement please return the defective part of your Hi Tech Transport Electronics product with proof of purchase to Hi Tech Transport Electronics Customer Support Department 1730 Willow Creek Circle Eugene Oregon 97402 USA Returns require an RMA number Call 888 459 3247 for an RMA number Hi Tech Transport Electronics Inc 1730 Willow Creek Circle e Eugene Oregon 97402 9152 USA P O Box 24308 Eugene Oregon 97402 0437 USA Telephone 541 343 7884 e Order Desk 888 459 3444 e Customer Support 888 459 3247 FAX 541 341 3121 Internet www Air Weigh com Copyright 1999 by Hi Tech Transport Electronics Incorporated All rights reserved Air Weigh ComLink WireLink 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 September 1999 Information contained in this literature was accurate at the time of publication Product changes may have been made after the copyright date that are not reflected 2 Conventions References to Air Weigh part names are type set in Italic References to sections within this manual are placed in quotes Procedures are designated by STEP Front Panel Function Key and Light names are type set in BOLD CAPITAL LETTERS General information such as Cautions and Notes are type set in talic2. Hi Tech Transport Electronics Inc Air Weigh DUAL LEVELING VALVE PROCESSOR INSTALLATION MANUAL For the 4600 Scale System For the 5600 Scale System September 1999 Air Weigh THE ACCURATE ON BOARD ELECTRONIC SCALE For Air Ride Trucks amp Trailers Patents 5 780 782 5 478 974 623 635 1 305 191 4 832 141 260 494 677 998 DUAL LEVELING VALVE PROCESSOR INSTALLATION MANUAL Limited Warranty Your Hi Tech Transport Electronics product is warranted against defects in material or workmanship for one year from the date of the original purchase Any Hi Tech Transport Electronics product which because of a manufacturing mistake or malfunction proves to be defective within the one year warranty period will be repaired or replaced at Hi Tech Transport Electronics option and at no charge to you provided it is returned to Hi Tech Transport Electronics with proof of purchase 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 Some states do not allow the exclusion or limitation of incidental or consequential damages so the above warranty does not apply in those states This warranty gives you specific legal rights and you may also have other rights which vary state to state Hi Tech Transport Electronics shall have no responsibility for overload fines received while using this product
3. cket STEP 6 Use a tie wrap to secure the Sensor Cables and the Disconnect Cable to the DSP housing STEP 7 Use four of the 1 4 inch bolts and nuts and the 8 washers to mount the DSP to the frame The washers should be placed on each side of the plastic DSP case at each hole Note Mount the DSP so the opening at the bottom points towards the ground STEP 8 FOR THE 4600 SCALE SYSTEM FOR THE 5600 SCALE SYSTEM Route the 60 ft Dual Sensor Cable loose end to Route the 3 ft Interconnect Cable loose end to the the 4 pin Disconnect Socket axle group RSP STEP 9 FOR THE 4600 SCALE SYSTEM Slide the heat shrink tubing over the cable Attach the cable to the disconnect socket according to the wiring diagram below Note The Dual Sensor Cable uses the white wire for the sensor signal output This wire must be attached to the sensor signal input of the 4600 The 4600 tractor sensor signal input uses the green wire Thus when the Dual Sensor Processor is used for the 4600 tractor the white Dual Sensor Cable wire must be attached to the green 4600 Sensor Cable wire Tractor Installation Dual Sensor Cable 4 pin Disconnect Socket RED RED BLACK BLACK WHITE GREEN Trailer Installation Dual Sensor Cable 4 pin Disconnect Socket RED RED BLACK BLACK WHITE WHITE Note Use the Solder N Seal lugs provided in your scale kit to splice the cable wires Refer to the scale installation manual for proper Solder N Seal lug insta
4. lation instructions STEP 2 Mount the sensor provided in the Dual Leveling Valve Processor kit on an air bag supplied by the second leveling valve Refer to the scale installation manual for the sensor installation instructions STEP 3 Plug one 6 ft Sensor Cable three pin plug into each right and left sensor socket 3B Install DSP STEP 1 Locate a flat vertical surface on the frame large enough to mount the DSP Note Make sure you place the DSP close enough to the pressure sensor for the 6 ft Sensor Cables to reach once they have been secured to the existing cables and wires Note When installing with a 5600 Scale system place the ComLink RSP close enough to the DSP for the 3 ft Interconnect Cable to reach once secured STEP 2 Rel z Hold the DSP in place using it as a template to mark the mount hole locations on the frame Caution Itis very important that the DSP be mounted so that moisture properly drains out the bottom When marking the mounting holes ensure that the DSP is level and that the drain hole is pointed down STEP 3 Insert each of the two 6ft Sensor Cable 5 pin plugs into a 5 pin socket on the back of the DSP Note Any one of the three DSP connectors may be used FOR THE 4600 SCALE SYSTEM FOR THE 5600 SCALE SYSTEM Insert the 60 ft Dual Sensor Cable 5 pin plug into Insert the 3ft Interconnect Cable 5 pin plug into the remaining DSP 5 pin socket the remaining DSP 5 pin so
5. llation instructions STEP 10 FOR THE 4600 SCALE SYSTEM ONLY FOR THE 5600 SCALE SYSTEM Attach the 3 ft Interconnect Cable to the ComLink RSP 5 pin socket This COMPLETES the 5600 Dual leveling valve processor installation Refer to the 5600 installation manual for further installation instructions Use the heat shrink tubing provided in your scale kit to bundle the installed Solder N Seal lugs This COMPLETES the 4600 Dual Sensor Processor installation Note The Dual Sensor Cable provided in your Dual Leveling Valve Processor Kit replaces the basic Sensor Cable provided in the standard 4600 Scale kit 4 Maintenance 4A Disconnects Periodically spray the 7 pin sockets and plugs with electrical cleaner A good electrical connection is vital for proper operation Make every effort to keep moisture out of the disconnect socket while the system is in operation 4B Dual Sensor Processor The Air Weigh Dual Sensor Processor should be maintenance free under normal operating conditions Ensure that the ComLink is mounted properly and keep the drain holes free of obstruction 4C Sensors Periodically inspect the sensor connections Do not grease the sensor plug in socket 5 Troubleshooting Problem the Dual Sensor Processor is not functioning Cause Solution The Dual Sensor Processor is not receiving power Verify the disconnect sockets are connected and There is no red or green light on the Dual Sensor wired c
6. nsecsssnsecsssnecssssnsossssnsecsssnsecsssnsesssensesssensecsssnnecsssnsesssensescenseesss 11 6 SUPPORT 11 1 Specifications 1A Dual Leveling Valve Processor Kit Total Weight of 4600 compatible kit Approximately 4 5lbs Total Weight of 5600 compatible kit Approximately 2 5 Ibs 1B Dual Sensor Processor DSP Note The Dual Leveling Valve Processor is labeled and referred to as a Dual Sensor Processor INPUTS 5 VDC From ComLink RSP 0 5 4 5 VDC From Sensor one 0 5 4 5 VDC From Sensor two OUTPUTS 5 VDC To Sensors 0 5 4 5 VDC Combined Sensor Signals to ComLink RSP DIMENSIONS W 6 3 8 inches L 5 inches H 3 3 8 inches 1C Pressure Sensor Air Pressure Capacity 0 150 psi Input Voltage 5 VDC From DSP Output Voltage 0 5 4 5 VDC To DSP Operating Temperature 45 to 135 C 1D Installation Torque all fittings until snug Be careful not to over tighten the fittings on the brass tee or the plastic of the airline may be damaged causing leakage 2 Installation Preparation 2A Component Description Electronic Pressure Sensors The pressure sensors measure the air pressure in your tractor and trailer air springs and convert the measurements to electronic signals Dual Sensor Processor The Dual Sensor Processor converts the electronic signals from two Electronic Pressure Sensors into one comparable signal This allows the appropriate Scale Display Module 4600
7. or 5600 to properly measure the weight of a single axle group controlled by two leveling valves ComLink Cable ComLink cable in a variety of configurations supports communications between components or with the vehicle s existing 7 wire electrical harness Each cable bears a label and has specific connectors for specific functions 2B Parts List Check the parts you need in the columns corresponding to the kit you will be installing Ifthe parts you need are not in your Air Weigh kit stop and contact your supplier AS SOON AS POSSIBLE Part description and part number 4600 Installation 1 Dual Leveling Valve Sensor Processor 050 4026 2 3 4 Sensor Fitting Cable Assembly 010 9082 Note The individual sensor fitting and assembly parts have been pre assembled into a single component 5 Mounting Bolts 420 x 1 131 4065 6 Mounting Nuts 132 4070 7 Mounting Flat Washers 133 5002 8 Nylon Wire Ties 145 4552 9 Dual Leveling Valve Processor Installation Manual 901 0000 10 Cable Sensor 6 010 8002 11 60 Sensor Cable 010 8015 12 Solder N Seal Butt Connectors 145 3031 383 3 Interconnect Cable 010 8014 14 Heat Shrink 380 0075 1 2C Pre Installation Considerations Required Tools 3 4 open end wrench 1 1 4 deep socket 1 1 4 open end wrench Torque wrench Drill pneumatic or electric 1 4 Drill bit Two 7 16 open end wrenches 5600 In
8. orrectly Processor Problem the Dual Sensor Processor has a solid red light Cause Solution The power and ground wires for the Dual Sensor Verify the disconnect sockets are connected and Processor have been reversed wired correctly 6 Support If you cannot correct a problem or you suspect you have a malfunctioning part please contact Air Weigh Product Support at 888 459 3247 Monday through Friday 8 AM 5 PM Pacific Time From outside the U S and Canada please call 541 343 7884 11 THE ACCURATE ON BOARD ELECTRONIC SCALE AirzWairgh Patents 45 780 782 85 478 974 623 635 41 305 191 44 832 141 260 494 677 998 1730 Willow Creek Circle e Eugene Oregon 97402 9152 USA P O Box 24308 Eugene Oregon 97402 0437 USA Telephone 541 343 7884 e Order Desk 888 459 3444 e Customer Support 888 459 3247 FAX 541 341 3121 Internet www Air Weigh com Information Contained in this literature was accurate at the time of publication Product changes may have been made after the copyright date that are not reflected 12
9. s and preceded by one of the following keywords Hint Hint gives you helpful information that is not required but helpful for y ou to know Caution Cautions warn you of actions that may cause injury to yourself or damage to equipment Remember This refers to important information that has been mentioned in previous procedures Note Notes provide you additional information aboutthe procedure that would otherwise not be covered Table Of Contents TA DUAL LEVELING VALVE PROCESSOR KIT eati ecelesie gite Potete teta ete a RNA 3 1B DUAL SENSOR PROCESSOR DSP INPUTS OUTPUTS DIMENSIONS 1C PRESSURE SENSOR ID iINSTAEEATION 7 ile nte istae tele anite r a a ecelesie 2 INSTALLATION PREPARA TION ccsscssssssssssssssssssnsecsssnsessssnsessssnsessssnsecsssnsessssnsessssnsossssnsecsssnsessssneessesnsossssnsecsssnuessssneessssnsessesnsecss 5 2A COMPONENT DESCRIPTION Electronic Pressure Sensor Dual Sensor Processor ComLink Cable 2B PARTS LIST 2C PRE INSTALLATION CONSIDERATIONS Required Tools For Best Installation Results BA INSTALE SENSORS teer ARA EAEAN AEA cis ege eset scored A Pee ele epe A tee ees De pets NRN nS 7 EI MM i O CCEPIT R 7 d MATIN TENANCE DT 10 4A DISCONNECTS 4B DUAL SENSOR PROCESSOR 4C SENSORS 5 TROUBLESHOOTING cccsssssssssssssccssssssssssnesssssnssssssnsccsssnsecsssnessssnsossss
10. stallation 4 1 1 4 0 1 1 For Best Installation Results WHAT YOU NEED TO KNOW The location of the most accessible air bag on the axle group you will be installing the DSP RECOMMENDATIONS Read through all the Installation Instructions prior to installing your Air Weigh scale and the DSP Do not wire tie cables until you have installed the entire kit successfully Leave plenty of slack in the ComLink cables during installation so they may be secured to the existing cables and wires To ensure that all cables and part connections meet properly map where the cables will be installed in you tractor and trailer before installation You may tailor the installation to your tractor and trailer Make notes for future installations Hint The ComLink Cables are not all the same length Determine where each cable will be installed prior to proceeding with the installation If you do not have enough cable to complete the installation contact your Air Weigh distributor or Air Weigh Product Support to receive the cable you need Caution For proper performance and safety this unit must be installed according to instructions Air Weighcannotbe responsible for problems accidents or defects arising from faulty installation 3 Installation 3A Install Sensors STEP 1 Mount the sensor provided with your scale on an air bag supplied by one of the leveling valves Refer to the scale installation manual for sensor instal
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