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Air Weigh BinMaxx XL Installation And User Manual

For front end loaders
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BinMaxx XL Office
Installation and
User Guide
for Front End Loaders
Air-Weigh Customer Support: 888-459-3247
PN 901-0153-000 R3

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Summary of Contents for Air Weigh BinMaxx XL

  • Page 1 BinMaxx XL Office Installation and User Guide for Front End Loaders Air-Weigh Customer Support: 888-459-3247 PN 901-0153-000 R3...

  • Page 2: Table Of Contents

    ComLink Interface Wiring Harness Connections....9 Installing the Display................10 Installing the Display Directly to the Dash......10 Installing the Display Using the Swivel Pod Mount ..10 Installing Hardware for BinMaxx XL........12 Installing the Date/Time Printer...........13 Installing the Proximity Sensors............14 Installing the Low Proximity Sensor...........14 Installing the High Prox Sensor T-Cable...........16...
  • Page 3 Final Touches..................32 Installing BinMaxx XL Office..............33 Installing the PC Application...............33 Installing the Drivers................35 Configuring the Base DataLink to Your PC........38 Pairing the DataLinks................40 Configuring the BinMaxx XL System............43 Assigning a Truck Number..............43 Enabling Spreadsheet Mode.............44 Using BinMaxx XL..................45 Downloading Information to Spreadsheets........45 Changing Download Settings.............46 Reading Spreadsheets................47 Converting Date and Time to Local Time Zone......49...

  • Page 4: Binmaxx Xl Overview

    BinMaxx scale and a GPS receiver and Bluetooth transmitter to be installed in the truck cab; you will need one of these kits for each vehicle. The BinMaxx XL Office kit contains the PC application needed to run BinMaxx XL and a Bluetooth receiver to set up the connection to the office computer. You will need one BinMaxx XL Office kit for all of your vehicles.
  • Page 5 This guide provides instructions for installing and configuring BinMaxx XL Office; all components of the Office kit, along with the Mobile DataLink from the BinMaxx XL kit, are shown in the above image. The Mobile DataLink is included in this image and throughout this manual because it will be needed in order to install BinMaxx XL Office.

  • Page 6: Binmaxx Overview

    BinMaxx Overview The BinMaxx Front-End Loader Scale calculates and displays the content weight of any bin to within 40 pounds and can display an accumulated net weight of all bins lifted. Users can also record the date and time of each lift using the optional Air-Weigh Date/Time Printer (part # 1250).

  • Page 7: Installation Overview

    Installation Overview There are three components of the BinMaxx scale you will install: • Cab electronic equipment: ComLink, interface cable, display, and the optional date/time printer • Low and high proximity sensors and cables • Deflection sensors with mounting brackets and cables For a full list of parts in your BinMaxx scale kit, see the Parts List included in your kit.

  • Page 8: Tools Required

    Tools Required You will need the following tools to install the deflection sensors on the steer and drive axles. • Sander/grinder • 40-grit medium sandpaper • Chalk or permanent marker • Drill and 5/8-inch hole cutter or drill bit • Flat-blade screwdriver • Adjustable wrench • 22 mm combination wrench • 22 mm socket and socket handle •...

  • Page 9: Installing The Cab Electronics

    Installing the Cab Electronics Installing the ComLink in the Cab Choose one of the three methods described on the following page to install the ComLink into the truck cab. We recommend that you install the ComLink in a place where it can be accessed fairly easily and will be safe from damage.

  • Page 10: Installing To An Existing Wiring Harness

    Installing to an Existing Wiring Harness Secure the ComLink to any appropriate existing wire harness using nylon ties secured through the holes on each side of the ComLink. Installing to a Flat Surface with Adhesive 1. Identify a location in the cab large and flat enough for the ComLink to rest on. 2.

  • Page 11: Installing The Comlink Wiring Harness

    Installing the ComLink Wiring Harness The 10-pin ComLink interface wiring harness connects the BinMaxx system to the vehicle’s electrical system and the display, and powers the low- and high-proximity sensors. See the following images for a map of the wiring harness and placement of connectors in the ComLink.

  • Page 12: Comlink Interface Wiring Harness Connections

    Follow the steps below to install the ComLink interface wiring harness. 1. Connect the wires as directed in Table 1. 2. Connect the 4-pin connector on the cable labeled “Low-Prox Connector into the corresponding port on the ComLink. The other end of the cable will be attached to the low-prox cable that comes from the proximity sensor.

  • Page 13: Installing The Display

    Installing the Display There are two methods you can use to mount the display in the cab. With the first method, the display adheres directly to the dash; with the second method, the display rests in the swivel pod mount, available upon request from Air-Weigh. Choose whichever method suits your needs better. Installing the Display Directly to the Dash 1.
  • Page 14 4. Mount the pod’s base using the double-sided tape or by screwing it directly to the dash. Use the provided drill template if you are using screws. When mounting with screws, you may need to remove the 1-inch by 2-inch display mounting base from the swivel before securing the base to the dash.

  • Page 15: Installing Hardware For Binmaxx Xl

    BinMaxx XL as a retrofit with an existing BinMaxx system, please follow the instructions on pages 4-5 and 8-9 to replace the ComLink and the display with the ones found in your BinMaxx XL kit that are compatible with the BinMaxx XL Office software. 1. Determine the best location on the dash for the GPS and Bluetooth devices.

  • Page 16: Installing The Date/Time Printer

    BinMaxx ComLink, you must replace the connector into the port of the ComLink and change the setup options in the display menu to use the printer with a scale set up for BinMaxx XL. Please see the BinMaxx User Guide for more information.

  • Page 17: Installing The Proximity Sensors

    Installing the Proximity Sensors All front-end loader vehicles work using two proximity sensors - one to signify that the arms have been raised (the “low prox” sensor) and one to signify that the arms have reached their highest position (the “high prox”...
  • Page 18 6. Route the low proximity sensor cable along the existing wiring to the driver’s side of the vehicle. Install zip ties as needed along the route. Leave the cable ties loose, as you will still need to run cables through them. 7.

  • Page 19: Installing The High Prox Sensor T-Cable

    Installing the High Prox Sensor T-Cable The T-cable is installed in line with the cabling of the existing high prox sensor. 1. Locate the high prox sensor and its cable Because the two existing prox sensor cables are both installed inside an insulation wrapper along a portion of their length, it may not be easy to tell which cable is the high prox sensor cable.

  • Page 21: Installing The Low Prox T-Cable (Residential Vehicles Only)

    Installing the Low Prox Sensor T-Cable (Residential Vehicles Only) McNeilus FEL vehicles identified as “Residential” have their standard low prox sensor installed in the location we normally use to install the BinMaxx low prox sensor. When installing BinMaxx on these vehicles, please follow the instructions below. Make sure you have ordered the second T-cable from Air-Weigh before beginning this installation.

  • Page 22: Installing The Deflection Sensors

    Installing the Deflection Sensors The deflection sensors measure the weight the bins place on the truck’s lift arms. BinMaxx uses two sensors, one for each arm. Each sensor is mounted with a bracket. Welding the Brackets to the Lift Arms 1. Assemble the jig installation kit as shown. Make sure the bracket halves are pushed flush against the spacer pins in the center of the jig and the space between the brackets is equal before tightening the bolts.
  • Page 23 3. Hold the assembled bracket and jig on the outside of the arm and line up the right edge of the assembled bracket with the 50-inch mark. Make sure the jig is resting along the bottom edge of the arm. The measurement from the top of the bracket to the bottom of the arm should be approximately 3.5 inches (4.2 inches for vehicles with Peterbilt chassis).
  • Page 24 4. Once you have selected the installation location, hold the bracket and jig assembly to the underside of the arm and adjacent to the scribe mark. Use C-clamps to hold it in place. 5. Using a permanent marker, mark the circumference of the bracket holes on the arm.
  • Page 25 6. Remove the C-clamp and bracket from the arm. Using a sander or grinder with 40-grit sandpaper, remove the paint on the arm to bare metal where indicated by the marker. Make sure there is no paint remaining where the bracket assembly will be welded.

  • Page 26: Placing The Deflection Sensors In The Brackets

    Placing the Deflection Sensors in the Brackets 1. Clean the deflection sensor and bracket mounting surfaces with the alcohol wipes supplied in your BinMaxx kit. 2. Place each deflection sensor in the bracket, oriented so that the sticker with the words “Bin-Maxx Only!” are facing down. 3. Using the washers, friction shims, nuts, and bolts from the deflection sensor installation kit, secure a deflection sensor to each bracket.

  • Page 27: Installing The Deflection Sensor Extension Cables

    Installing the Deflection Sensor Extension Cables There are two cables for deflection sensors located in your BinMaxx kit. They will be labeled “Deflection Sensor - Left” and “Deflection Sensor - Right.” The left sensor cable should be installed on the driver’s side; the right cable should be installed on the passenger side. Follow the steps below to install the cables. 1.

  • Page 28: Setting The A/D Values

    Setting the A/D Values At this point, you have installed all of the BinMaxx system components. You will next adjust the deflection sensors to read weight correctly by setting their A/D values. Please note that “A/D” refers to the analog-to-digital conversion of the sensor reading. First Sensor Torque 1. To assemble the connectors, insert the deflection sensor connector plug into the sensor extension cable connector OR connect to the deflection sensor test box. Make sure the locking tabs on the connector plug are securely connected.
  • Page 29 2. Tighten both nuts and use a torque wrench to torque to 60 foot-pounds. 3. If you are using the scale menu to find A/D values, follow the steps below. • Start the vehicle ignition to turn on the display. • Press ESC to reach the main menu. • Use ▲ or ▼ to select DIAGNOSTICS. Press ENTER. • Use ▲ or ▼ to select ECU. Press ENTER. • Use ▲ or ▼ to select SENSOR DATA. Press ENTER.

  • Page 30: Correcting Your A/D Reading

    Correcting Your A/D Reading 1. If the A/D reading is below 750 or there is no A/D reading at all, follow the instructions below. Otherwise, go to Step 2. • Loosen the nut on the cable end of the sensor. •...

  • Page 31: Adjusting The Low Proximity Sensor

    Adjusting the Low Proximity Sensor To accommodate all sizes of bins, the low-proximity switch should be set to turn on when the tallest bin is lifted a few inches off the ground. 1. Start the truck and wait for the scale to power up. 2.
  • Page 32 6. Turn the truck power on, but do not start the vehicle. Wait for the BinMaxx scale to power up. 7. From the scale display, follow the steps below. • Press ESC to reach the main menu. • Use ▲ or ▼ to select DIAGNOSTICS. Press OK. • Use ▲ or ▼ to select ECU. Press OK. • Use ▲ or ▼ to select SENSOR DATA. Press OK.
  • Page 33 the forks. If properly set, the low prox switch should not be on during the entire time the forks are lower than the low prox target height. 13. Re-measure the fork height to make sure the forks are the distance from the ground that you identified in Step 3. 14.

  • Page 34: Completing The Installation

    Completing the Installation Verifying the High Prox Sensor Operation 1. Start the vehicle. • After the BinMaxx scale has finished powering on, follow the steps below on the display. • Press ESC to reach the main menu. • Use ▲ or ▼ to select DIAGNOSTICS. Press OK. • Use ▲ or ▼ to select ECU. Press OK. • Use ▲ or ▼ to select SENSOR DATA. Press OK. • The A/D readings will display on the BinMaxx screen. Press ▼ until you see the data that reads PROX SWITCHES along with values.

  • Page 35: Seating The Deflection Sensors

    Seating the Deflection Sensors After the BinMaxx installation is complete and before you calibrate, we recommend you flex the arms of the vehicle to “seat” the deflection sensors. 1. Start the vehicle and lower the forks. 2. Place a bin filled to the approximate weight of a heavy bin on your daily route onto the vehicle forks. 3. Lift the weight above the windshield and then lower it 20 to 30 times.

  • Page 36: Installing Binmaxx Xl Office

    Installing BinMaxx XL Office You will only need to install BinMaxx XL Office once. If you are installing BinMaxx XL on a new truck but have already installed BinMaxx XL Office, please skip this section. Note: At this time, BinMaxx XL does not support versions of Windows older than Windows 7. Please install the application on a computer that is running Windows 7 or higher.

  • Page 38: Installing The Drivers

    Installing the Drivers The Base and Mobile DataLinks will not run on your PC unless you have installed drivers for the devices. Follow the instructions below to install drivers. 1. The BinMaxx USB drive should still be connected to your computer.
  • Page 39 4. Click Complete to finish installing the driver. 5. Go back to the BinMaxx USB drive folder and find the file labeled Keyspan-Driver.exe. Double-click to open the file. 6. You will see the screen which reads “Please Wait While InstallShield Wizard Prepares the Setup.” After a few seconds the screen will ask you to check your account privileges. Make sure you have the ability to install new programs on the office PC. Then click Next.
  • Page 40 8. The wizard will show a folder where the driver will be installed. For most installations, the default folder is correct. Click Next. 9. The screen will read Configuring. Wait until the bar finishes loading; then the screen will read Installation Complete. Click Finish to complete the installation.

  • Page 41: Configuring The Base Datalink To Your Pc

    Configuring the Base DataLink to Your PC 1. Insert the BinMaxx XL Base DataLink and antenna into an open USB port on your computer. If the office PC is not near a window, use the 10’ USB extension cable to mount the Base DataLink as close to a window as possible. This will give you a better connection between the base and mobile datalinks.
  • Page 42 Record or remember this number. 6. Go back to the BinMaxx XL application. Find the drop-down menu that reads Select Comm Port and select USB Serial Port from the drop-down menu.

  • Page 43: Pairing The Datalinks

    Base DataLink and the Mobile DataLink. The one in use by the Mobile DataLink will read Keyspan. Each port should have a communication port number listed next to it. Record or remember these numbers. 5. Close and re-open the BinMaxx XL application. Your Base Datalink should already be plugged into your computer.
  • Page 44 6. From the BinMaxx XL application, click on the Setup BinMaxx tab. 7. Select the correct communications port for the Keyspan device from the drop-down menu. Click Check for Mobile DataLink. 8. When the program finds the Mobile Datalink, the Datalink’s Bluetooth address, which is a 12-digit series of letters and numbers, will be visible on the screen. The configuration status should read Setup Ready. Record the BlueTooth...
  • Page 45 9. Click Setup. The configuration status should then read Setup Pending and, after a few seconds, Configured Successfully. 10. Go to My Documents and open the folder entitled BinMaxx XL. Look for a document entitled “truck_list0.txt.” Open this document. 11. Check to see if the Bluetooth address you just configured is in the text of this document. If it is not, paste or type the address into the document.

  • Page 46: Configuring The Binmaxx Xl System

    Without one, BinMaxx XL Office will not be able to read your truck’s information. Truck numbers also help you differentiate between trucks if you have multiple vehicles with BinMaxx XL installed. 1. Turn on the truck and wait for the BinMaxx scale to power on. 2. From the display menu, press ESC to reach the BinMaxx scale main menu.

  • Page 47: Enabling Spreadsheet Mode

    Enabling Spreadsheet Mode The default factory setting for a new BinMaxx XL scale is set to spreadsheet mode. However, a retrofit BinMaxx scale will not necessarily be set to spreadsheet mode. We recommend that you follow the instructions below to enable spreadsheet mode before using the BinMaxx XL application to transfer data.

  • Page 48: Using Binmaxx Xl

    Downloading Information to Spreadsheets 1. Once BinMaxx XL has been installed in all vehicles, turn the ignition switch on all vehicles. Scales should power up. 2. Open the BinMaxx XL office application and select the Reader tab.

  • Page 49: Changing Download Settings

    This step should be performed after each successful download of a vehicles data. This will erase the data stored on the vehicles BinMaxx XL ComLink. This function can also be performed by the vehicle vehicle operatuor using the BinMaxc XL display - see the BinMaxx User Guide for more information.

  • Page 50: Reading Spreadsheets

    GPS coordinates of the lift on a map. Note: Do NOT delete the file titled Truck List.txt, located in the same folder as the final spreadsheets the program generates. This text file is vital to the functionality of the BinMaxx XL program.

  • Page 52: Converting Date And Time To Local Time Zone

    Converting Date and Time to Local Time Zone The spreadsheet generated by the BinMaxx XL program includes the date and time of each lift. By default, though, this date and time displays in Greenwich Mean Time. In order to display the time in your local time zone, follow the steps below to convert the time in the spreadsheet to the correct time.

  • Page 53: Troubleshooting

    2. Make sure the BinMaxx display is turned on and is displaying text (the vehicle must be powered on). 3. Open the BinMaxx XL folder that has been installed in your office PC’s Documents folder. Look for the file truck_list0. txt. Open the file and make sure that the vehicle’s Bluetooth address is included in the text of the file.

  • Page 54: Application Freezes Or Will Not Refresh

    The BinMaxx XL Application Freezes or Will Not Refresh 1. Close the application and re-open the application. 2. If this does not eliminate the problem, please call our Support department. The Application Shows an Error When Pairing DataLinks If you click Setup on the Setup BinMaxx page and see a red error...

  • Page 55: Uninstalling Binmaxx Xl

    Removing a Truck from the Truck List If the BinMaxx XL hardware installed in one truck is not in use, that truck will not appear on the truck list in BinMaxx Office. However, if you plan to use BinMaxx in the truck but no longer want to send data to BinMaxx XL Office, follow the steps below.

  • Page 56: Limited Warranty

    Limited Warranty For product failures due to material or manufacturing defects, Air-Weigh will replace or repair all components for up to three 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.

  • Page 57: Procedure For Warranty Claims

    Procedure For Warranty Claims ALL customers should first contact Air-Weigh Customer Support Department at (888) 459-3247 for questions regarding the use, operation, repair or return of any Air-Weigh product. In the event Air-Weigh requests to examine the product prior to disposition OR for repair or replacement, Air-Weigh requires a Return Material Authorization (RMA) number be issued before the item is returned.

  • Page 58: Notes

    Notes...
  • Page 59 1730 Willow Creek Circle • Eugene, OR 97402-9152 USA P.O. Box 24308 • Eugene, OR 97402-0437 USA Telephone (541) 343-7884 • Order Desk (888) 459-3444 Customer Support (888) 459-3247 • Fax (541) 431-3121 Hours of Operation: Monday - Friday, 7 a.m. - 5 p.m., PST www.Air-Weigh.com...

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