nexxiot Kingpin Monitor 1.0 T3000/MAZ80800 Sensor Instruction Manual
- June 6, 2024
- nexxiot
Table of Contents
Kingpin Monitor 1.0
T3000/MAZ80800 Sensor
Installation Manual
| Doc. Nr.: | 20211102004 |
|---|---|
| Version: | 1.2 |
| Status: | APPROVED |
| Classification: | PUBLIC |
© 2021
Change history
| Version | Author | Publication | Reason for change |
|---|---|---|---|
| 1.2 | Nexxiot AG | 2022-01-11 | Magnet holder Update |
| 1.1 | Nexxiot AG | 2021-11-10 | QR/NFC Update |
| 1 | Nexxiot AG | 2021-11-02 | Translation from the German original |
Warnings
2.1 Disclaimer
The Kingpin Monitor 1.0 system does not replace the manual checking of the
hitch condition during loading or unloading by the wagon master! It is only to
be understood as a support of this process! Nexxiot AG assumes no liability
for damages including consequential damages of any kind caused by faulty
assembly of the sensors or displays!
2.2 Adhesive
The processing times specified in this document are based on the
manufacturer’s data sheet and may vary depending on the ambient temperature!
Specifically: All data are based on a laboratory temperature of 24°C, at a
higher ambient temperature the curing reaction is accelerated and thus
shortens the open processing time. At a lower ambient temperature, the curing
reaction is slowed down and thus prolongs the open processing time.
If gluing is required at very high or very low temperatures, please contact
the manufacturer for further assistance! (EBS GmbH)
Before assembly
3.1 Contents of the Kingpin mounting kit for the sensor variant: T3000
- 1x Kingpin sensor housing with inscription «Type: T3000»
- 2x Kingpin Display
- 1x magnet (20x10x1mm) in magnetic cover
- 1x Spacer I-Part
3.2 Required tools
- Kingpin test adapter to test correct functionality
- Aid for degreasing: detergents, spatulas, cleaning cloth
- Test display or display from sensor kit
3.3 Mounting Aids:
-
Template 1:
Magnetic leg for holding down the housing until adhesive hardens -
Template 2:
Template for positioning the housing and the magnet -
Holding magnet: to fix the Kingpin sensor during adhesive hardening
3.4 View of the mounting position after installation
The figure shows an inverted support bracket including the mounting positions
of the housing and the external cable sensor.
- Kingpin Sensor
- A magnet for locking sensor
Assembly steps
Important: Please follow all steps in the instructions in the exact order
and don’t skip any step!
4.1 Cleaning of adhesive surfaces
Before gluing, clean the surfaces circled in green (see also a mounting
picture from section 1.2) where the housing surfaces rest so that they have a
clean surface for gluing.
It is imperative to roughen the adhesive surfaces with sandpaper so that the
adhesive adheres optimally!
- Degrease, roughen up and Clean green marked areas inside the hitch!
4.2 Gluing the spacer (I-part)
The spacer is necessary to minimize the deflection of the locking leg towards
the sensor housing, thus preventing the locking leg from bumping into the
housing.
Identify the gap on the cone side where the metal leg is directed outwards for
locking.
The adhesive surface must be degreased, roughened (sandpaper), and cleaned
before bonding!
Now apply 2K glue to the I-part and press it to the top of the gap until the
glue has dried (about 10min).
If the I-part does not fit into the gap due to manufacturing tolerances
of the supporting trestle, grind off material until the Apart sits
appropriately in the gap.
Now continue working quickly, because the 2K adhesive has a processing time
of about 4-7 minutes after which the mixing nozzle is unusable.
Squeeze some glue out of the cartridge every 2-3 minutes so that the mixing
nozzle does not clog.
4.3 Fix QR Code Sticker with integrated NFC Tag on Hitch
Take the QR Code Sticker which is supplied inside the Kingpin Kit Package and
attach it on the hitch as seen below. Make sure to degrease, roughen and
clean the surface before fixing the sticker on the hitch!
https://id.nexxiot.net/nfc/04F247F2956780
4.4 Activation of the sensor
The sensor is activated by holding a metal part to the Kingpin sensor for
at least 15s and then removing it again.
After 15s without metal nearby, the display shows the actual sensor
status for 5 seconds when tapping the button after a short double light of the
two left LEDs.
4.5 Fix the sensor housing using the 2K adhesive
Make sure that the Kingpin Adapter is inserted in the funnel! The sensor
housing in white must be attached to the base plate by gluing. Apply
appropriate 2K adhesive to the bottom of the Clean Case. The 2K adhesive can
be supplied in black or white.
Be careful when touching and inserting the housing, do not smear the
glue!
1. ATTENTION!
Remove the rubber knob!
Otherwise, template 2 cannot be applied correctly later
2. ATTENTION!
2 Component adhesive must not smear on the base plate (adhesive plate) when
inserting the housing up to the final position!
A 5mm gap between the leg and base plate allows this!
Info:
Let the case rest in an approximate position on the leg until the fine
adjustment is made with the template
Apply Template 2:
Apply template 2 as shown below and then press the template + case against the
base plate.
Note the parallel contact pressure in the direction of the arrow!
Apply Template 1:
Place template 1 so that the other half of the case is also pressed against
the base plate.
Now continue working quickly, because the 2K adhesive has a processing
time of about 4-7 minutes after which the mixing nozzle is unusable.
Squeeze some glue out of the cartridge every 2-3 minutes so that the
mixing nozzle does not clog.
4.6 Test mounting of the magnet inside the magnetic holder
Carefully place the magnet inside the stencil opening in the direction
shown below.
Then press the magnet against the metal leg so that it snaps into place, see
the detailed view at the bottom left.
- Direction sensor housing
- Direction Spring
Snap the sensor into place on both sides of the metal leg!
4.7 Remove the stencil
If 10 minutes have passed since the sensor housing was glued, carefully remove
stencil 2 by dragging it down, with slight resistance from the retaining
magnets.
4.8 Checking the locking sensor:
Unlocking of a few millimeters back the pin should result in a transition of
the right two LEDs from BLUE (penultimate LED) to RED (last LED from left to
right) on the display within a few seconds.
To do this:
- Place the display near the locking lever and tap the display. This should indicate BLUE as far as the two right LEDs are concerned (Locked)
- Unlock the support bracket only halfway (the pin should only retract a few millimeters ) and hold the lever in position while tapping the display again one or more times.
- The status should now jump from blue to RED (rightmost red LED)
- Unlock to stop and the status should remain on RED.
4.9 Re-attach stencil 2 for bonding
Re-create template 2 for the subsequent bonding of the magnet.
4.10 Fix magnet in the magnetic shell
Apply some 2K glue to the magnetic surface and carefully place the magnet in
the direction shown below in the stencil gap.
Then press the magnet against the metal leg so that it snaps into place, see
the detailed view at the bottom left.
4.11 Fix the kingpin sensor
Make sure the Kingpin adapter is in the funnel!
Then apply the adhesive over the entire surface shown below.
Note: If the 2K adhesive is already too hard, use a new mixing nozzle!
Use the enclosed retaining magnet when pressing the sensor housing against
the mounting surface.
There should be a gap of 2mm between the funnel pin and the housing
surface!
The KP sensor must be mounted by 3mm graded to the funnel!
Functional test of the complete system
Check the function of the sensors by inserting and removing the Kingpin Adapter into the hitch as well as by locking and unlocking the locking bar.
-
Insert the Kingpin Adapter into the support bracket and check whether the LEDs light up blue-blue when locked:
-
Now unlock the support bracket and check whether a blue-red combination lights up:
-
Now remove the Kingpin Adapter and check whether the LEDs light up red-blue when locked:
-
Now unlock the support bracket and check whether a red-red combination lights up:
Display Installation & Pairing of Kingpin Kit with Globehopper
The two displays of the sensor kit are already paired in advance with the
respective sensor of the kit (receiving only signals from this sensor).
Please follow the assembly instructions of the displays for mounting on
the wagon.
Please use the pairing app to connect the sensors and the displays to the
respective telematics main device (Globehopper/Connector) of the wagon.
Contact us:
Prime Tower, Hardstrasse 201,
8005 Zurich, Switzerland
+41 44 275 5151
[email protected]
www.nexxiot.com
www.nexxiot.com