Air Weigh BinMaxx XL User manual

PN 901-0153-000 R3
Air-Weigh Customer Support: 888-459-3247
BinMaxx XL Ofce
Installation and
User Guide
for Front End Loaders

ii
Table of Contents
BinMaxx XL Overview...............................................................................1
BinMaxx Overview....................................................................................3
Installation Overview..............................................................................4
Tools Required........................................................................................5
Optional Tools..........................................................................5
Installing the Cab Electronics..................................................................6
Installing the ComLink in the Cab.......................................................6
Installing to an Existing Wiring Harness...............................7
Installing to a Flat Surface with Adhesive............................7
Installing to a Flat Surface with Screws...............................7
Installing the ComLink Wiring Harness...............................................8
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
Installing the Low Prox T-Cable (Residential Vehicles Only).........18
Installing the Deection Sensors...........................................................19
Welding the Brackets to the Lift Arms...............................................19
 PlacingtheDeectionSensorsintheBrackets..............................23
 InstallingtheDeectionSensorExtensionCables.........................24
Setting the A/D Values............................................................................25
First Sensor Torque.............................................................................25
Correcting Your A/D Reading.............................................................27

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Final Sensor Torque............................................................................27
Adjusting the Low Proximity Sensor....................................................28
Completing the Installation....................................................................31
Verifying the High Prox Sensor Operation.......................................31
 SeatingtheDeectionSensors.........................................................32
Final Touches.......................................................................................32
Installing BinMaxx XL Ofce.................................................................33
Installing the PC Application...............................................................33
Installing the Drivers............................................................................35
 ConguringtheBaseDataLinktoYourPC.....................................38
Pairing the DataLinks.............................................................................40
Conguring 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
Troubleshooting....................................................................................50
A Vehicle Does Not Appear in the Truck List....................50
Application Freezes or Will Not Refresh............................51
Application Shows Error When Pairing DataLinks...........51
Uninstalling BinMaxx XL....................................................................52
Removing a Truck from the Truck List...............................52
  UninstallingBinMaxxXLOfce...........................................52
Limited Warranty.....................................................................................53
Procedure For Warranty Claims............................................................54
Notes.........................................................................................................55

1
BinMaxx XL Overview
BinMaxx XL allows the user to measure the content weight of each
bin, records the lift number and GPS coordinates of the truck on
eachlift,andcansendallliftinformationwirelesslytoanofce
PC. BinMaxx XL can be installed on multiple trucks, and the user
can access and manage all truck information from a single PC
application.
Truckinformationissavedin.csvleformat,whichiscompatible
with Microsoft Excel and other spreadsheet programs. This
informationcanthenbemodiedasnecessaryandexportedinto
the company’s routing and/or billing systems.
There are two separate components necessary for installing and
using BinMaxx XL. The BinMaxx XL scale kit contains a complete
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OfcekitcontainsthePCapplication
needed to run BinMaxx XL and a Bluetooth receiver to set up the
connectiontotheofcecomputer.YouwillneedoneBinMaxxXL
Ofcekitforallofyourvehicles.
Throughout this manual, the Bluetooth transmitter in the truck cab
is referred to as the Mobile DataLink, while the Bluetooth receiver
installedontheofcePCisreferredtoastheBase DataLink.For a
full list of parts in your BinMaxx scale kit, see the Parts List included
in your kit.

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Thisguideprovidesinstructionsforinstallingandconguring
BinMaxxXLOfce;allcomponentsoftheOfce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Ofce.

3
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). The weights of individual lifts can be printed
immediately, or all lift measurements can be printed at a later time.
This installation guide provides information for installing BinMaxx
scaleswithpartnumbers1710and1711,whicharespecically
designed for McNeilus front end loaders.
The BinMaxx kit for McNeilus vehicles includes a dash-mounted
display, a BinMaxx ComLink module, two proximity sensors, arm
deectionsensors,armbrackets,andallrequiredcables.

4
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
• Deection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.

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Tools Required
Youwillneedthefollowingtoolstoinstallthedeection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
• Torque wrench
• Epoxy paint (color-match truck)
• Welder, MIG or ARC
• E7018 welding electrodes (if using an ARC welder)
• E70S-3 or E71T-1 welding wire (if using a MIG welder)
• C-clamps
• Tape measure
• Wire cutters
Optional Tools
• Deectionsensortestbox,availablefromAir-Weigh(P/N
1001)

6
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. We have found that one of the best
installation locations is under the cab access panel.
.

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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atenoughforthe
ComLink to rest on.
2. Clean the surface using one of the alcohol pads supplied in
the installation kit. Remove all dust, grease, and debris from
the surface.
3. Remove the red strips from the back of the ComLink,
exposing the adhesive tape.
4. Press the ComLink against the cleaned area using steady
force. Be careful not to crack the case.
Installing to a Flat Surface with Screws
InstalltheComLinkusingself-tappingscrewstoanyatlocation
available in the cab.

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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.

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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.
3. Connect the 10-pin connector to power port on the ComLink
(reads “Power/Ground/Aux Out/Display”).
4. Secure the wiring using nylon ties as needed.
Table 1: ComLink Interface Wiring Harness Connections
Wire Description Wire Connection
White Chassis ground
Blue changes to black
with in-line fuse
12VDC or 24VDC key-on power
source
Gray Not used
Brown Not used
Black (two wires) Not used

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Installing the Display
There are two methods you can use to mount the display in the
cab.Withtherst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. Select a location on the dash where the display will be easy
for the driver to see and where the buttons are easy to
access.
2. Clean the surface using one of the alcohol pads supplied in
the installation kit. Remove all dust, grease, and debris from
the surface.
3. Connect the display cable to the ComLink. Then run the
display cable through the hole to the display and install the
display cable connector onto the display.
4. Remove the adhesive tape backing from the display and
adhere the display to the dash over the 1/2-inch hole.
Installing the Display Using the Swivel Pod Mount
1. Identify a location on the dash where you will mount the pod.
Make sure the location is not blocked and provides the best
viewing angle without obstructing the driver’s view of the
road.
2. Verify that the display cable is long enough to reach from the
ComLink to the display before mounting the cable.
3. If necessary, drill a 1/2-inch hole in the dash to run the display
cables from the ComLink to the display. If there is an existing
access hole for other dash-mounted devices available, use it
if possible.

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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.
5. Remove the mounting base from the swivel base assembly.
6. Place the adhesive strips provided in your kit on the back of
the new display, but
be careful not to
cover the cable slot.
Usingrm,even
pressure, adhere
the display onto the
dash or mounting
base.
7. Connect the display
cable to the display
and press cable into routing groove.
8. Attach the display and
base onto the pod swivel
assembly.
9. Adjust the display until it
sits at the desired angle.
10. Tighten the handle to
secure the display to the
swivel mount.

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Installing Hardware for BinMaxx XL
This manual assumes that you are installing a new BinMaxx system
that includes the BinMaxx XL components. If you are installing
BinMaxxXLasaretrot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Ofcesoftware.
1. Determine the best location on the dash for the GPS and
Bluetooth devices. Both should be mounted out of the way
of other sensors and in a location that does not obstruct
the driver’s view. We recommend installing them on the
passenger’s side of the vehicle.
2. If possible, use the existing hole for the display cable to run
the GPS and Bluetooth cables to the ComLink. If necessary,
drill additional holes into the dash to allow the Bluetooth and
GPS cables to connect to the ComLink.
3. Clean the dash where you will mount the Bluetooth and GPS
devices using the alcohol pads found in your hardware kit.
Let the alcohol dry.
4. Attach the 5dBi antenna to the Bluetooth Mobile DataLink
and tighten. Remove the backing from the VHB mounting
tape and secure it to the bottom of the Bluetooth device.
Pressthedeviceontothedashsmoothlyandrmlytoensure
a secure adhesion. Leave enough room so that the antenna
will stay vertical.
5. Repeat the above step to secure the GPS device to the dash.
6. Thread the Bluetooth and GPS cables through the dash
holesidentiedorcreatedinStep2.

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7. Connect the ends of the GPS and Bluetooth cables into the
ComLink. The Bluetooth cable should be plugged into the
port that reads “Printer/RS232.” The GPS cable should be
plugged into the port that reads “GPS In,” on the far left of the
ComLink.
8. Place the ComLink back in the dash where it was installed.
Close and re-fasten the dash.
Installing the Date/Time Printer
Air-Weigh offers an optional date/time printer that can be installed
with your BinMaxx scale. It can be used to print all weight data as
well as the date and time of printing. For information on installing the
date/time printer, please see document 901-0105-000, available on
request from Air-Weigh Support or on our website.
Please note that you cannot use the date/time printer and BinMaxx
XL simultaneously. Although both can be installed and used with
one 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.

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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” sensor). BinMaxx for McNeilus requires the installation
of one additional low proximity sensor and an additional high prox
T-cable, included in the BinMaxx kit.
Proximity sensors, targets, and proximity sensor brackets installed
at the factory are in accordance with McNeilus documentation.
Note: If you are installing BinMaxx on a residential-type front
end loader, you will need two high prox T-cables (one is
included in the scale kit). Contact Air-Weigh if your installation
requires two T-cables. Please see p. 17 for installation
instructions.
Installing the Low Proximity Sensor
1. Remove the proximity sensor, lock washer, and cable from
their packaging.
2. Make sure the truck’s arms are in the stowed position.
3. Locate the existing proximity sensors and bracket (near the
torque arm tube on the passenger side of the vehicle).
4. Install the proximity sensor and lock washer into the bracket.
Hand-tighten only.
5. The distance from the center of the high prox sensor to the
center of the new low prox sensor should be approximately 2
and 1/8 inches.

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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. Connect
the low
prox sensor
extension
cable to the low prox cable connector.
8. Runtheremaininglengthofthecablethroughthecabrewall
and into the cab.
. Connect the cable to the low prox connector on the ComLink
wiring harness.
Note: Please ensure that there is a minimum of 12 inches
between the wiring and the exhaust piping, or properly shield
wiring to protect it from heat.

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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.
2. Follow the cable to its connectors, located behind the cab,
and unplug the high prox cable connector.
3. Place the T-cable along the existing prox sensor cables. Pull
the cable through any loose nylon ties that have already been
installed along the route.
4. Route the remaining length of cable into the cab through the
rewallandtowardtheComLink.
5. Install the connector from the T-cable into the HIGH PROX
port on the ComLink.

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