SFWR0016 : AirWeigh BinMaxx Scale – Documentation & Troubleshooting

Description:

This document is intended on providing documentation and Basic TroubleShooting from FleetMind Support end on the AirWeigh BinMaxx scale.

Documents Links: 

Air Weigh BinMaxx 2019
BinMaxx Operator Instruction
BinMaxx Diagnostic Worksheet
BinMaxx Data Stream on RS232 Port

Issue:

Following are the issues

  1. BinMaxx Scale not showing any readings
  2. Scale not being integrated and showing negative values
  3. In WasteApp getting an error in Vehicle Status as an exclamation sign, not reading weight lifts and no visibility on the scale

Resolution:

Following troubleshooting steps are taken when resolving the AirWeigh BinMaxx issues:-

Checking AD Readings

  1. Turn the vehicle on to power the scale.
  2. Turn on your scale display. Press ESC until you see PRINT, ERASE blinking.
  3. Scroll down to DIAGNOSTICS and press OK.
  4. Scroll down to ECU and press OK.
  5. SENSOR DATA will be blinking. Press OK.
  6. The screen will display LT SENSOR and RT SENSOR with numerical values. These are your A/D readings. These numbers should be between 500 and 1500.
  7. If your sensors are not between 500 and 1500, please see “Setting A/D Values for Deflection Sensors” shown below, for instructions on how to set the values correctly.

NOTE:

After initial installation, or anytime after the sensors have been reset, and prior to the “break-in procedures” being performed (see below for break-in procedures and explanation), the A to D readings should be between 750 and 1250. Anytime after the “break-in procedures” have been performed, the acceptable reading is between 500 and 1500.

A to D readings should ONLY be checked when there is NO WEIGHT ON THE FORKS and the torque tube is lowered close to the ground.

Setting A/D Values for Deflection Sensors

1. Gather the following tools: 120 ft-lb. capable Torque wrench, 22mm socket, Ladder & Air-Weigh deflection sensor test box (p/n 1001) or use the in-cab display diagnostics menu seen on the page above to view the AD readings throughout this process.

2. If A/D reading is BELOW 500:

  •  Loosen both nuts on the sensor.
  •  Exert downward pressure with your finger on the plastic nut found at the end of the cable side of the sensor until you reach an A/D reading between 750 and 1250.
  •  Torque the nut on the non-cable end of the sensor to 60 ft-lbs while maintaining the required AD reading via continuing finger pressure on the plastic nut.
  •  Repeat this process on the cable end of the sensor.
  •  If the A/D readings are still within the proper range when both bolts have been torqued to 60 ft-lbs, proceed to Step 4, if not repeat these steps under Step 2.

3. If A/D reading is ABOVE 1500:

  •  Loosen both nuts on the sensor.
  •  Exert upward pressure with your finger on the plastic nut found at the end of the cable side of the sensor until you reach an A/D reading between 750 and 1250.
  •  Torque the nut on the non-cable end of the sensor to 60 ft-lbs while maintaining the required AD reading via continuing finger pressure on the plastic nut.
  •  Repeat this process on the cable end of the sensor.
  •  If the A/D readings are still within the proper range when both bolts have been torqued to 60 ft-lbs, proceed to Step 4, if not repeat these steps under Step 3.

4. Final sensor torque:

  •  Complete tightening the nut on the non-cable end of the sensor FIRST by torquing to 120 ft-lbs.
  •  Complete tightening the nut on the cable end of the sensor NEXT by torquing to

5. 120 ft-lbs.

  •  Perform a final check of the A/D values. If not within range, repeat steps 2 or 3 and then 4.
  •  If using the Deflection Sensor Test Device, disconnect the test fixture and connect the deflection sensor cable to the sensor extension cable.

Seating Arm Sensors

Sensor seating needs to take place any time after

the torque on the weighing sensors has been adjusted.

  1. Start the vehicle and lower the forks.
  2. Place a container filled with some type of non-liquid material on the vehicle forks.
  3. Lift the weighted container above the windshield and then lower it about 20 times. Do not worry if the lift process is slightly jerky, but be careful not to let the bin touch the ground.
  4. When you have lifted and lowered the container approximately 20 times, the seating process is complete. This repeated lifting and lowering will “seat” the hardware associated with the deflection sensors so that they do not move minute amounts and cause inaccurate weight readings.
  5. Check the A to D readings to ensure that they are now between 500 and 1500. If they have moved beyond this range, the sensors will again need re-torqued and the seating procedures also will then need to be performed again. It is a very rare occurrence that this would occur.

Checking Prox Switch and Target Distance

When either the low or high-prox switch is NOT activated (i.e. the target plate is NOT in front of the appropriate prox sensor), the value displayed for that sensor should be between 0 and 5. When either the low or high-prox switch IS activated (i.e. the target plate IS in front of the appropriate prox sensor), the values displayed should be a four-digit number.

A two or three-digit sensor reading is an indication that the prox sensor is either too far away from the target plate or that there may be a problem with the cabling either being cut or dysfunctional.

  1. Start the truck. Lower the fork torque tube so that it is near the ground.
  2. On the BinMaxx display, enter the following key sequence:
  • Hit ESC until DIAGNOSTICS displays at the bottom of the screen
  • Scroll down to DIAGNOSTICS and press OK
  • Scroll down to ECU and press OK
  • Scroll down to Sensor Data and press OK
  • Scroll down to Prox Switches and press OK

3. Slowly raise the fork torque tube until the LO PROX reading on the display changes from a single-digit number to a four-digit number. Try to stop your movement at the EXACT spot at which the change from a single-digit number to a four-digit number occurs. Measure to see how far the center of the fork torque tube is from the ground, at the EXACT spot that the change took place. This needs to be approximately 50” from the ground (anywhere between 48” to 52” is fine). If it is not, proceed to “IF THE LO PROX ACTIVATION HEIGHT IS OUT OF SPEC” seen below to adjust the activation height.

4. Next, slowly raise the fork torque tube until the HI PROX reading on the display changes from a single-digit number to a four-digit number. Try to stop your movement at the EXACT spot at which the change from a single-digit number to a four-digit number occurs. Measure to see how far the center of the fork torque tube is from the ground, at the EXACT spot that the change took place. This needs to be approximately 100” from the ground (anywhere between 98” to 102” is fine). If it is not, proceed to “IF THE PROX ACTIVATION HEIGHT IS OUT OF SPEC” seen below to adjust the activation height.


IF THE PROX ACTIVATION HEIGHT IS OUT OF SPEC

(Non-McNeilus FEL)

  1. Locate the proximity sensors and their target plates, typically on the passenger side on the torque tube. The prox sensors will be hanging from a holder that is welded to the body and the targets will be wrapped around the torque tube via a band clamp.
  2. With the center of the fork torque tube already sitting at either 50” from the ground for setting the LO prox or 100” from the ground for setting the Hi prox, loosen the screw on the band clamp that holds the target plates and that wraps around the torque tube, relevant to the sensor on which you are adjusting.
  3. Rotate the target plate so that it is just beginning to activate (i.e. changing from a single digit to a four digit reading).
  4. Tighten the screw on the band clamp that wraps around the torque tube, ensuring that it does not slip at all during this process.
  5. Start the vehicle. Make sure that the BinMaxx display is still showing Prox Switches information. If it is not, follow the instructions in Step 4 above to show the correct display readings for the prox sensors.
  6. Lower the forks a few inches. The LO PROX display should read between 0 and 5. Raise the forks slowly until the LO PROX display changes and immediately stop raising the forks. Re-measure the fork torque tube height to make sure the tube is between 48” and 52” from the ground for the LO Prox or 98” to 102” for the HI prox. Repeat steps 1 thru 4 until the desired fork heights have been obtained.

 

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