Air Weigh BinMaxx User manual

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PN 901-0177-000 R2
Air-Weigh Customer Support: 888-459-3247
BinMaxx
Installation Guide
For Front End Loaders

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Table of Contents
BinMaxx Overview...........................................................................1
Installation Overview.....................................................................1
Tools Required.................................................................................2
Installing the Deection Sensors..................................................3
Choosing a Location for the Brackets........................................3
 WeldingtheDeectionSensorBrackets...................................4
 InstallingtheDeectionSensorExtensionCables.................6
 PlacingtheDeectionSensorsintheBrackets.......................7
InstallingtheProxSensorCables..............................................8
Installing the Proximity Bracket and Sensors..............................9
 WeldingtheProxSensorBracket.............................................10
 InstallingtheLowandHighProxSensors..............................10
 AssemblingandInstallingtheProxSensorTargets..............11
Installing the Cab Electronics.......................................................11
Installing the ComLink.................................................................12
 InstallingtoanExistingWiringHarness..................................12
Installing the ComLink Wiring Harness......................12
 InstallingtheDisplay....................................................................14
 SettingtheA/DValues................................................................14
  FirstSensorTorque.......................................................15
  AdjustingtheA/DReading...........................................16
  FinalSensorTorque......................................................17

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Adjusting the Proximity Sensors.................................................18
 AdjustingtheLOPROXSensor................................................18
 AdjustingtheHIPROXSensor.................................................20
Completing the Installation..........................................................21
 FinishingTouches.......................................................................21
Notes...............................................................................................22
Limited Warranty...........................................................................23
Procedure for Warranty Claims...................................................24

1
BinMaxx Overview
TheBinMaxxscalecalculatesanddisplaysthecontentweight
ofanycommercialcontainerasitisliftedanddumped.Users
canalsorecordthedateandtimeofeachliftusingtheoptional
Air-WeighDate/TimePrinter.
Installation Overview
TherearethreecomponentsoftheBinMaxxscaleyouwillinstall:
• Cabelectronicequipment:ComLink,interfacecable,scale
display
• Lowandhighproximitysensorsandcables
• Deectionsensorswithmountingbracketsandcables
Location of BinMaxx Kit Components

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Tools Required
• Grinderandmediumgritapperdisc
• Chalk or permanent marker
• Drilland5/16inchsocketandadapter
• Adjustablewrench
• 22mmsocketand120ft./lb.torquewrench
• Spraypaint
• Welder,MIGorARC
• C-clamps
• Tapemeasure
• Wirecutters
• AlignmentTool(callAir-Weighforpricing)
Optional Tools
• Deectionsensortestbox(P/N1001),availablefrom
Air-Weigh
A/D Box (P/N 1001)

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Installing the Deection Sensors
Thedeectionsensorsmeasuretheexintheliftarmsasthetruck
raisesandlowersbins.BinMaxxusestwosensors,oneforeach
arm.Eachsensorismountedtoasetofarmbracketsoneachside
ofthetruck.
Choosing a Location for the Brackets
• Thebracketsshouldbeasclosetotheupperforward
curve(closesttotheforksofthetruck)whileremaining
level(i.e.notinthecurve).
• Thebracketsshouldnotbeplacedoveranyhydraulic
clamps,couplersorotherhardware.(OEMweldsmay
needtobegrounddowninordertoplacetheBinMaxx
armbracketinthemostoptimumlocation.)
• Thebracketsand/orarmsensorscannotbeincontact
withanyothertruckcomponent,suchasanarmmounted
hydrauliclineoranarmcable.
• Thebracketsneedtobeplacedinthesamepositionon
botharms.Verifypositioningonbotharmspriortowelding
thebracketsoneitherside.Ensurethattheposition
chosen does not have any interference on either side.
• Thebracketsshouldbeplacedsothatthereisenough
spacetoinstallorremovethedeectionsensors.Leave
thealignmenttool(Jig)inthebracketduringweldingto
ensurethatthereisenoughspace.
• If an arm weld seam or plug is located in the optimum
position for the arm
brackets, grind the arm weld
seam down until it is smooth
and ush with the arm and
then position and weld the
arm sensor brackets to that
location. Positioning of
the scale’s brackets must
supersede the existence
of any OEM welds when a
conict occurs.
Placing the Bracket on the Lift Arm

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Welding the Deection Sensor Brackets
1. Assemblethejiginstallationkit(alignmenttool),asshown
above.Makesurethebrackethalvesarepushedush
against the spacer pins in the center of the jig and the space
betweenthebracketsisequalandconsistentbeforeand
aftertighteningthebolts.
2. Holdthebracket/jigassemblytotheundersideofthearm
overthelocationyouchoseforinstallationearlier.Thebottom
oftheJshapedbracketshouldfaceinboardtowardsthecab
tooptimizetheprotectionofthearmsensor.UseC-clampsto
holdthebracket/jiginplace.
3. Usingapermanentmarker,markthecircumferenceofthe
bracketholesonthearm.
4. RemovetheC-clampandbracket.Removethepaintonthe
armtobaremetalwhereindicatedbythemarker.Makesure
thereisnopaintremainingwherethebracketwillbewelded.
5. Replacethebracketoverthesandedareaandsecurethem
in place with the C-clamps.
Assembling the Bracket and Alignment Tool Jig (# 111-0025)

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6. Conrmbracketsareushagainstarmwithnointerference
fromtubeclamps,armwelds,etc.
7. UsingaMIGorARCwelder,tack-weldinsidethetwobracket
holes(top,bottom,left,andright,asindicatedabove)and
then weld the circumference of the hole. Do not weld in
any other location.
8. Whentheweldsarecompletelycooled,removethe
C-clamps.
9. Removethetwoboltsfromthebracketandjigassemblyand
removethejig.Paintthebracketandanybaremetal.Avoid
gettingpaintinsideofthebracketwhereitcradlesthesensor.
10.Repeatthesteps1-9onthesecondarm.
Small Black Circles Indicate Tack-Weld Locations
Tackweldthe
top,bottom,
right and left of
eachcircle.Thenthe
entirecircumference.

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Installing the Deection Sensor Extension Cables
Therearetwoidenticalshortcables(#014-1450-113)andtwoidentical
longextensioncables(#014-3550-085)usedforconnectingthe
deectionsensorstotheComLinkinthecabofthetruck.Plugoneshort
cableintoonelongcableandlabelonesetrightandonesetleftbefore
youbegininstallation.TheLEFTsensorcableshouldbeinstalledonthe
driver’sside;theRIGHTcableshouldbeinstalledonthepassengerside.
1. Alongtheexistingarmhydrauliclinesandwiring,routetheshort
cable(#014-1450-113)oneachside(driverandpassenger)from
thegapbetweenthearmbracketsdownthearm.Thelongcable
(#014-3550-085)plugsintotheshortcableandthenextends
tothecab.Makesuretooptimizetheroutetoprotectthecable.
Alsoensurethattheprotectiveheatshieldfoundonthetwoshort
cablesispositionedinthelocationswiththemostpotentialheat
exposure.Improperinstallationcouldresultindamagetothe
cable.Thelongsensorcable(approx35-feetlong)willconnectto
theshortcableandbeinstalledinthedirectionofthecabtobe
connected to the ComLink.
2. Beginning12”fromthebackendofthebackarmbracket,attach
thesensorextensioncable
tohydrauliclinesalongthe
armwithziptiesevery6”(#
014-1450-113).
3. Atthebottomofthearm,
routetheremaining35’
extensioncableintothecab
ofthetruckalongexisting
truckandbodycables.
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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Placing the Deection Sensors in the Brackets
1. Placeeachdeectionsensorinthebracket,orientedsothatthe
engraved lettering is facing down and so that the pigtail on the
sensor is facing toward the front of the truck.
2. Usingthewashers,nuts,andboltsfromthedeectionsensor
installationkit,securethedeectionsensortoeachbracket
asshownabove.Hand-tightenthebolts(doNOTusetoolsto
tighten).
3. Curlthesensorpigtailcablebehindthearmbrackettoprotect
thecableandconnector.Donotallowthecableorconnectorto
contacttheblackrubbermiddlesectionofthesensor.
4. Connecttheshorterextensioncabletoitsdeectionsensoron
eachside,makingsurethatthelockingtabsontheconnector
areengagedcompletely.Useziptiestosecurethepigtailand
connectortotheexistinghydrauliclinesrunningbehindthe
bracket.
Deection Sensor and Bracket Assembly
4. Inthecabofthetruck,connecttheright-sidedeection
sensorextensioncabletotheportlabeled“RightSensor”
ontheComLink.(Repeatontheleftside.)ComLinkwillbe
installed in later step.

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Installing the Proximity Bracket and
Sensors
BinMaxxrequirestheinstallationoftwoproximitysensors,along
withtheircorrespondingbandclamptargetsandbracket.
Thereareavarietyoflocationswhereyoucansuccessfullyinstall
theproxsensorbracketandbandclamptargets,dependingonyour
vehiclemanufacturer.
Possible Congurations for Bracket and Targets

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Findalocationonthebodyapproximatelytwoinchesfromthearmtube
tomounttheproxbracketandbandclamptargets.Theproxsensorswill
needtofacethearmtubewherethebandclamptargetswillbeinstalled.
Thebracketwillbendtotallbodytypes.
1. Cut,orscoreandbend,thesensorbracketasshortaspossible.
Excesslengthcanleadtowobblingthatwillcausetheproximity
sensortolosecontactwiththetargetplate.Aftercuttingorbending
thebrackettothedesiredconguration,besuretostabilizethe
brackettopreventwobblebyweldingtothebrackettheAir-Weigh
provided1’steelrod,partnumber110-0209-000.Thisrodcanalso
becut,ifneeded.
2. Thebracketandbandclamptargetsshouldnotinterferewithany
componentsonthebody.
3. Thereshouldbeenoughspacetoaccessand
tightentheboltsonthebandclamptargets.
Welding the Prox Sensor Bracket
1. Bendormodifythebrackettotinthelocation
youhavechosenforinstallation.
2. Usingtheprovidedpieceofsteel,cutandweld
thereinforcinggusset.A12”steelbarhasbeen
providedforyourconvenience.
3. Usingagrinder,cleartheareawherethe
bracketwillbelocateduntilnothingremainsbut
baremetal.
4. Weldthebrackettotheinstallationlocation.
Installing the Low and High Prox Sensors
1. Placeanutandlockwasherontheendofeachproxsensor.
2. Passthehighproxsensorthroughtheholeinthebracketthatis
facingtowardtheoutsideofthevehicle.
3. Passthelowproxsensorthroughtheholethatisfacingtowardthe
center of the vehicle.
Reinforced using
(provided) steel bar

10
Placement of the Targets and Prox
Sensors
Prox Target Orientation on the Arm Tube
Assembling and Installing the Prox Sensor Targets
Theproxsensortargetsattachedtothebandclampsareused
toactivatethelowandhighproxsensors.Note:youwillneedto
performanaladjustmentlaterintheinstallationprocess.
1. Locatethetwoproxtargetbandclampsandtargets.Thread
thetargetontothebandclamp.
2. Placetheclampswiththetargetsonthearmtubeandclose,
butdonottighten.
3. Slideeachtargetandplacethemsotheyaredirectlyunder
thefrontoftheproxsensors.
4. Withtargetcenteredunderthefrontofeachsensor,adjust
theproxsensorssotheyareseparatedfromthetargetsby
1/8to3/16ofaninch.
5. Tightenproxsensorscrewssotheywon’tmove.
4. Placethesecondnutandlockwasheroneachproxsensor
andhandtighten.Youwilladjustthemlater.

11
Installing the Prox Sensor Cables
1. Locatethetwo30-footproxsensorextensioncablesinthe
BinMaxxscalekit.
2. Labeltheendsofthecablesthatwillbeinstalledinthecab(LO
andHI).
3. Connecttheappropriateproxcableendstothecooresponding
proxsensorpigtailcables;oneforLOandoneforHI.
4. Routethecableintothecab(usuallythroughtheoororrewall)
tobeconnectedtotheComLink.
5. Connectthelowproxcabletotheinterfacejumperwireandthen
thelowproxportontheComlink.Repeatwiththehighproxcable
andport.(seeComLinkWiringHarnessdrawingonpage14for
identication).
6. Securecableswithziptiesasnecessary.
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.
Installing the Cab Electronics
Installing the ComLink
DonotinstalltheComLinkinanopenareaofthecab.Werecommend
installingtheComLinkinaplacewhereitcanbeaccessedfairlyeasily
andwillbesafefromdamagesuchasunderanaccesspanelorinthe
doghouse.
Install to an Existing Wiring Harness
SecuretheComLinktoanyappropriateexistingwireharnessusing
ziptiessecuredthroughtheholesoneachsideoftheComLink.

12
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.Seeimage
onnextpageforamapofthewiringharnessandplacementof
connectors in the ComLink.
Follow these steps to install the ComLink interface wiring
harness:
1. Connectthewhitewiretochassisground,andconnectthe
bluewiretokeyhotpowersource(Donotconnectdirectlyto
ignitionswitch).
2. Connectthe4-pinconnectoronthecablelabeled“High-Prox
Connector”intothecorrespondingportontheComLink.The
otherendofthecablewillbeattachedtothehigh-proxcable
thatcomesfromtheproximitysensor.
3. 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.
4. Connectthe10-pinconnectortopowerportontheComLink
(reads“Power/Ground/AuxOut/Display”).
5. Securethewiringusingziptiesasneeded.

13
ComLink Connections
ComLink Interface Wiring Harness
Cloud
E
In-LineFuse Black WIre White Wire BlueWire
5800EDisplay
Connector Twoblackwires GrayWire,
NotUsed
High-Prox
Connector
BrownWire,
NotUsed
Low-ProxConnector

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Installing the Display
1. Selectalocationonthevehicledashwherethedisplaywill
beeasyforthedrivertoseeandwherethebuttonsareeasy
to access from the driver’s seat.
2. Verifythatthedisplaycableislongenoughtoreachfromthe
ComLinktothedisplaybeforeinstalling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.
4. Cleanthedashsurfaceusingoneofthealcoholpads.
5. Ifyouhaveamountingpodskiptostep7.Connectthe
displaycabletotheComLink,thenrunthecabletothe
display and connect it.
6. Removetheadhesivetapebackingandadherethedisplay
using15lbsofpressurefor60-seconds.
7. Mountthepod’sbaseusingthedouble-sidedtapeorscrewit
directlytothedash.Usetheprovideddrilltemplateifyouare
usingscrews.
8. Connectthedisplaycabletothedisplayandpressthecable
intotheroutinggroove.
9. Adjustthedisplayuntilitsitsatthedesiredangle.
10.Tightenthehandletosecurethedisplaytotheswivelmount.
Setting the A/D Values
Atthispoint,youhaveinstalledalloftheBinMaxxsystem
components.Youwillnextadjustthedeection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.
WhensettingtheA/Dvalues,theforktubesneedtobeclosetothe
ground,withouttouchingtheground.Theforksshouldbepointing
upwards,towardsthesky.

15
First Sensor Torque
1. RemovethenutsandaddthesuppliedThreadlocker242
Loctite©orequivalenttothethreadsyoujustexposedand
replace.
2. Ensurethattheboltheadisintheboltheadholder.The
boltheadshouldbefacingtowardthetruckandthethreads
shouldbefacingawayfromthetruck.
Note: Step 3 can be skipped, if you are using
the test box (Air-Weigh optional part number
1001). Turn on the test box and plug arm
sensor pigtail into A/D box cable. Deection
sensor A/D readings will be displayed
immediately on the screen. Continue with step
3 if using in-cab display.
3. UsethepromptsbelowtondtheA/D
values:
• 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
• TheA/DreadingswilldisplayontheBinMaxxscreen
4. Inthispreliminarystep,tightenbothnutswithatorque
wrenchto60foot-pounds.
5. Ifthereadingiswithincorrectrange(750to1250)inthis
preliminarystep,continuetoinstructionsfortheFinal Sensor
Torque.Ifnot,continuetoAdjusting the A/D Reading
sectionbelow.
A/D Box (P/N 1001)

16
A/D Box (P/N 1001)
Adjusting the A/D Reading
If the A/D reading is above 1250, follow these instructions
1. Loosenthenutsonbothendsofthesensor.
2. Attheplasticnutwherethecableentersthesensor,exert
UPWARDpressurewithyourngeruntiltheA/Dreadingis
between750and1250,(1000isanidealreading).Continueto
applypressuretomaintainthedesiredA/Dreadingduringthe
torqueprocedures.
3. TightenthenutontheNON-CABLEsideto60ft/lbsrst,
whilemaintainingtheA/Doutputatareadingbetween750
and1250byexertingtheproperpressurewithyournger
onthemoldednutatthecableendofthesensor;repeatthis
processforthenutonthecablesideofthesensor. IftheA/D
readingsarestillwithinthe750to1250rangeafterthenuts
onbothsidesofthesensorhavebeentorquedto60ft./lbs.,
continuetoinstructionsfortheFinal Sensor Torque.
If the A/D reading is below 750, follow the steps below
1. Loosenthenutsonbothendsofthesensor.
2. Attheplasticnutwherethecableentersthesensor,exert
DOWNWARDpressurewithyourngeruntiltheA/Dreading
isbetween750and1250(1000isanidealreading).Continue
toapplypressuretomaintainthedesiredA/Dreadingduring
thetorqueprocedures.

17
3. TightenthenutontheNON-CABLEsideto60ft/lbs,while
maintainingtheA/Doutputatareadingbetween750to
1250byexertingtheproperpressurewithyourngeron
themoldednutatthecableendofthesensor;repeatthis
processforthenutonthecablesideofthesensor.IftheA/D
readingsarestillwithinthe750to1250rangeafterthenuts
onbothsidesofthesensorhavebeentorquedto60ft./lbs.,
continuetoinstructionsfortheFinal Sensor Torque.
Final Sensor Torque
1. Tightenbothboltsto120ft/lbs.
2. PerformanalcheckofA/Dvaluesusingthereadingsfrom
thein-cabBinMaxxdisplay,notfromtheADbox.IfA/D
readingsarenotwithinrange,repeattheAdjusting the A/D
reading steps.