eqss Gen-3 LMS User manual

EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for JCB 5 1-70 Waste Master
VER: 20150320
Failure To Follow Installation Manual Will Void Warranty

Documentation Conventions
The list below highlights important do umentation onventions.
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Text presented in this manner is intended to provide the user
with some general information. The user should ensure
information presented in this manner is clearly understood.
Text presented in this manner provides the user with
information to assist in completion of the current procedure
being explained.
Text presented in this manner indicates that a failure to follow
directions could result in damage to equipment, loss of
information, bodily harm, or loss of life.

Important Information
Information ontained in this publi ation regarding this devi e's appli ations and the like is
provided only for your onvenien e and may be superseded by updates. It is your
responsibility to ensure that the appli ation or our equipment meets with your
spe ifi ations.
EQUIPMENT SAFETY SYSTEMS MAKE NO REPRESENTATIONS OR WARRANTIES
OF ANY KIND WHETHER EXPRESS OR IMPLIED, WRITTEN OR ORAL, STATUTORY
OR OTHERWISE, RELATED TO THE INFORMATION, INCLUDING BUT NOT LIMITED
TO ITS CONDITION, QUALITY, PERFORMANCE, MERCHANTABILITY OR FITNESS
FOR PURPOSE.
Equipment Safety Systems dis laims all liability arising from this information and its use.
Use of Equipment Safety Systems’ produ ts as riti al omponents in life support systems
is not authorised ex ept with express written approval by Equipment Safety Systems. No
li enses are onveyed, impli itly or otherwise, under any Equipment Safety Systems
intelle tual property rights.
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Table of Contents
Tools Required for Installation.....................................................................................5
Installation Index...........................................................................................................6
overs.........................................................................................................................10
able Reeler Installation.............................................................................................12
able Reeler Mounting Position.............................................................................14
Pressure Sensor Installation.......................................................................................15
Main ylinder Pressure Sensors............................................................................15
ompensation Pressure Sensors............................................................................17
Reverse amera..........................................................................................................19
Forward amera..........................................................................................................21
Light Tower Installation..............................................................................................23
Light Tower Bracket Mounting Position................................................................24
an Pressure Input Module ( PIM)............................................................................25
External able ompletion.........................................................................................27
an abin Interface Module ( IM)...........................................................................29
Dashboard Switches....................................................................................................30
Display Installation......................................................................................................31
Machine onnections..................................................................................................32
Finalisation..................................................................................................................35
Sensor alibration.......................................................................................................38
Indexes and Tables.....................................................................................................40
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Tools Required for Installation
The tools required to perform the installation of the TSS are listed below
•Pen il or Texta
•Drill
•Drill bits
◦3.3 mm
◦4.5 mm
◦5 mm
◦6.25 mm
◦6.8 mm
◦8.5 mm
•Centre pun h
•Tap T-Handle
•Taps
◦M6
◦M7 x 0.75
◦M8
•Drill and tap oil
•Metri Allen keys
•Phillips Head s rew driver
•Spanners and so kets
◦7 mm
◦10 mm
◦13 mm
•Lo ktite thread lo ker
•Side utters
•Stanely knife
•Crimpers
•Wire strippers
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Installation Index
The omponents and ables of the Gen-3 Telehandler Load Management System are
outline in the tables below. The following pages show where the omponents are installed
and the able routing.
See the appropriate manual se tion for a detailed installation des ription for ea h
omponent.
Refer to this section for any component placement or cable
routing issues
Item omponent Description
1 able Reeler
2 Main Lift ylinder Head Pressure Sensor
3 Main Lift ylinder Rod Pressure Sensor
4 an Pressure Input Module ( PIM)
5 Forward amera
6 Light Tower
7 an abin Interface Module ( IM)
8 Display Module
Table 1: Component Installation Index
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olour able Description
Red Boom able
Dark Green Main ylinder Head Pressure Sensor able
Brown Main ylinder Rod Pressure Sensor able
Dark Blue ompensation ylinder Pressure Sensors ables
Light Blue Forward amera able
Violet Light Tower able
Aqua Rear amera able
Dark Purple IM able
Light Green utout Harness
Dark Yellow Machine Input Harness
Light Purple Height Limiter able
Orange Display able
Table 2: Cable Installation Index
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Illustration 1: Machine Boom
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Illustration 2: Machine Chassis
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Covers
Remove the following overs before starting the installation
Step Description Diagram
1. Release the dashboard display bolts
2. Remove the indicator display behind
the steering wheel
3. Release the cover beside the
joystick
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Step Description Diagram
4. Remove the side panel next to the
cabin under the boom.
5. Remove the covers under the boom.
Table 3: Cover removal
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Cable Reeler Installation
The able reeler is used to measure the boom extension to determine the maximum lifting
apa ity.
Step Description Diagram
1. Drill and tap the holes for the cable
reeler according to the mounting
diagram on page 14.
Mount using the supplied M6 x 12
mm bolts and washers.
2. Drill and tap an M8 hole for the
cable anchor. Ensure the cable
anchor is positioned so the cable
runs in line with the boom.
Mount the cable anchor and secure
the cable to the anchor.
3. Drill and tap the M6 holes for the
stow switch trigger. Ensure the stow
switch is pressed when the boom is
retracted.
Mount the stow switch trigger using
the supplied M6 x 30 mm bolts and
17 mm standoffs.
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Step Description Diagram
4. onnect the supplied M12 10 metre
cable ( B001027) into the cable
reeler connection.
5. Run the cable along the hydraulic
pipes running down the boom,
secure using cable ties every 150
mm to 200 mm.
able tie to the flexible hydraulic
hoses down to the chassis. Make
sure the cable isn't pinched or
stretched when the boom is raised
or lowered.
Run the cable towards the cabin and
cable tie with the other cables
during External able ompletion on
page 27.
Table 4: Cable Reeler Installation
For further details on running the boom cable refer to the
Installation Index on page 6
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Cable Reeler Mounting Position
Illustration 3: Cable Reeler Mounting osition
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Pressure Sensor Installation
The hydrauli pressure sensors are used to measure the lifting load of the telehandler.
Main Cylinder Pressure Sensors
Step Description Diagram
1. Raise the boom to approximately 40
degrees.
Support and secure the boom using
an A Frame or similar apparatus. It
must support at least 2 tons.
Apply the handbrake and insert
chock under wheels.
Release the blanking cap on the
hydraulic tee.
Removing the blanking cap will
release the hydraulic pressure which
may result in a spray of oil.
Install the supplied pressure sensor
and ensure it is tightly sealed.
2. Install the tee connector and
pressure sensor into the rod of the
main lift cylinder, where the flexible
hose is connected to the solid hose
on the chassis under the lift
cylinder.
Start the machine, pressurise the
boom and check for leaks.
View from under the main lift
cylinder
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Step Description Diagram
3. onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
able tie the head pressure sensor
cable to the flexible hydraulic hoses
connected to the main lift cylinder.
Make sure the cable isn't pinched or
stretched when the boom is raised
or lowered.
Run the cables towards the cabin
and cable tie with the other cables
during External able ompletion on
page 27.
Table 5: ressure Manifold Installation
For further details on running the pressure sensor cables
refer to the Installation Index on page 6
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Compensation Pressure Sensors
Step Description Diagram
1. Release the cover behind the
machine.
Undo the hydraulic connection for
the head compensation into flexible
hydraulic line at the rear of the
machine.
Install the supplied tee piece and
pressure sensor in line with the
hydraulic connection.
2. Undo the hydraulic connection for
the rod compensation into flexible
hydraulic line at the rear of the
machine.
Install the supplied tee piece and
pressure sensor in line with the
hydraulic connection
Start the machine, pressurise the
boom and check for leaks.
3. onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
Add both cables to 2 m of snake
tube.
Run the snake tube and cables
towards the cabin and cable tie with
the other cables during External
able ompletion on page 27.
Table 6: Compensation ressure Sensor Installation
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Angle the tee connections to ensure the hydraulic connections
and pressure sensor do not hit the boom when the boom is
lowered
For further details on running the pressure sensor cables
refer to the Installation Index on page 6
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Reverse Camera
The rear amera video is displayed on the s reen when the ma hine is in reverse gear to
allow the operator to see behind the telehandler while reversing.
Do not disconnect the camera power connection while the
system is operating as this can damage the fuse.
Step Description Diagram
1. Drill a 31mm hole in the location
shown. Making sure to leave enough
room for a license plate
Insert the camera through the hole
and adjust the angle using the
alignment washers.
2. onnect the camera power and
signal connectors to the supplied 5m
camera cable ( B001032).
Note; The white connector is not
used.
Secure the camera cable to the
license plate light cables
Run the remainder of the cable
towards the cabin and cable tie with
the other cables during External
able ompletion on page 27.
Table 7: Reverse Camera Installation
The camera's viewing angle may need to be adjusted once the
system is installed and the display is operational.
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For further details on running the camera cable refer to the
Installation Index on page 6
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