eqss Gen-3 LMS User manual

EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for
JCB 55 -8 /56 -8 Agri Plus (Waste Master)
PLEASE NOTE:
VER: 1906171309
Failure To Follow Installation Manual Will Void Warranty
***Failure To Follow Installation Manual Will Void Warranty***
***Do Not Swap Components between Gen3-LMS kits***
When installing multiple Gen3-LMS kits, make sure the serial
number on the sticker matches the serial number on the
machine.

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provided only for your onvenien e and may be superseded by updates.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, IT'S 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
Covers...........................................................................................................................
Cable Reeler Installation...............................................................................................8
Cable Reeler Mounting Position.............................................................................10
Pressure Sensor Installation.......................................................................................11
Main Cylinder Pressure Sensors............................................................................11
Compensation Pressure Sensors............................................................................13
Reverse Camera..........................................................................................................14
Forward Camera..........................................................................................................15
Signal Light Installation..............................................................................................17
Can Pressure Input Module (CPIM)............................................................................19
External Cable Completion.........................................................................................21
Can Cabin Interface Module (CCIM)...........................................................................23
Dashboard Switches....................................................................................................24
Display Installation......................................................................................................25
Machine Connections..................................................................................................27
Finalisation..................................................................................................................31
Set Time & Sensor Calibration...................................................................................35
Appendix A: Attaching Display Connectors...............................................................38
Appendix B: Reattach Ferrites...................................................................................42
Indexes and Tables.....................................................................................................43
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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
•Hole saw
◦31 mm
◦34 mm
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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.
A false N07 fault can occur if the boom jumps off the stow
switch due to pressurising the hydraulic system and without
operating the boom extension control. Ensure the stow switch
arm is correctly adjusted to prevent this error.
Step Description Diagram
1. Drill and tap the holes for the cable
reeler according to the mounting
diagram on page 10.
Mount using the supplied M x 30
mm bolts and 17 mm standoffs.
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.
Drill and tap the M 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 M x 30 mm bolts and
17 mm standoffs.
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Step Description Diagram
3. Connect the supplied M12 10 metre
cable (CB001033) into the cable
reeler connection.
4. Run the cable along the hydraulic
pipes running down the boom,
secure using cable ties every 150
mm to 200 mm.
Cable 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 Cable Completion on
page 21.
Table 4: Cable Reeler Installation
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Cable Reeler Mounting Position
Illustration 1: Cable Reeler Mounting Position
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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 port labelled M1.
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.
Note: The pressure sensor may
need to set on a diagonal angle to
ensure the sensor is not crushed
when the boom is fully lowered
View from the under the boom to the
counterbalance valve on the lift
cylinder
2. Locate the 5/8 BSPP to 3/8 BSPP
Hydraulic Tee (Not Supplied, JCB #:
81 /90143) and connect to rod
pressure sensor connections using
the supplied seal as shown.
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Step Description Diagram
3. Install the tee connector and
pressure sensor into the rod of the
main lift cylinder, where the flexible
hose is connected to the rod port on
the side of the lift cylinder.
Start the machine, pressurise the
boom and check for leaks.
4. Connect the supplied M12 4 metre
cables (CB00102 ) into each of the
pressure sensors.
Cable tie the pressure sensor cables
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 Cable Completion on
page 21.
Table 5: Main Cylinder Pressure Sensor Installation
Angle the tee connections to ensure the hydraulic connections
and pressure sensor do not hit the boom when the boom is
lowered
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Compensation Pressure Sensors
Step Description Diagram
1. Undo the hydraulic connection for
the flexible hydraulic line into the
head for the left compensation
cylinder on the side of the boom.
Install the supplied tee piece and
pressure sensor in line with the
hydraulic connection.
2. Undo the hydraulic connection for
the flexible hydraulic line into the
rod for the left compensation
cylinder under the boom.
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. Connect the supplied M12 10 metre
cables (CB001033) into each of the
pressure sensors.
Run the cables along the hydraulic
lines down to the chassis towards
the cabin and cable tie with the
other cables during External Cable
Completion on page 21.
Table 6: Compensation Pressure Sensor Installation
Angle the tee connections to ensure the hydraulic connections
and pressure sensor do not hit the boom when the boom is
lowered
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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.
Insert the camera through the hole
and adjust the angle using the
alignment washers.
Connect the camera power and
signal connectors to the supplied 5m
camera cable (CB001032).
Note; The white connector is not
used.
Run the remainder of the cable
towards the cabin and cable tie with
the other cables during External
Cable Completion on page 21.
Table : 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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Forward Camera
The forward amera video is displayed on the s reen when the ma hine is in forward gear
to allow the operator to see past the boom to obstru tions that would damage the right
front tyre.
Do not disconnect the camera power connection while the
system is operating as this can damage the fuse.
Step Description Diagram
1. Mount the camera to the side mirror
using the p-clips in the location
shown.
Secure using two M nuts.
Connect the camera power and
signal connectors to the supplied 5m
camera cable (CB001032).
Note; The white connector is not
used.
Note: The old light tower is shown.
2. Run the cable along the mirror
support structure toward the
chassis, then under the chassis to
the side of the cabin.
Cable tie with the other cables
during External Cable Completion on
page 21.
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Table 8: Forward 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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Signal Light Installation
The signal light warns other workers when the telehandler is lifting loads lose to it's
maximum apa ity.
Ensure the power supply voltage is greater than 13.5V
otherwise the signal light may not illuminate correctly.
Step Description Diagram
1. Remove the magnet from the bottom
of the signal light mounting bracket
and flip the signal light mounting
bracket so the mounting holes are on
the bottom.
Cut and remove 0.5 m of snake tube
from the end of the cable starting at
the signal light.
Drill two M4 holes to mount the
signal light bracket to the left
headlight support bracket on the
roof.
Note: The signal light can instead be
mounted to the right headlight
support bracket for better protection
but reduced visibility.
Mount using the supplied M4 bolts
and nuts.
2. Inside the cabin, remove the covers
at the top of the windshield and at
the side housing the LMI indicator.
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Step Description Diagram
3. Cut the signal light cable
approximately 300 mm from where
the cable exits out the base of the
signal light.
Feed the cable through one of the
existing grommets for the headlight
cable into the cabin.
Note: As an alternative to cutting the
cable the grommet hole can be
enlarged to fit the M12 connector.
Note: The signal light cable must be
run through an existing grommet
hole. Drilling another hole in the
cabin will invalidate the ROPS/FOPS
protection of the cabin.
4. Inside the cabin, cut off
approximately 2 m to shorten the
cable. Then reconnect the 4 wire
cable using the supplied crimp
joiners.
Secure the joined connections using
electrical tape (not shown)
5. Run the cable along the same path
as the headlight cables to inside the
dashboard and secure using cable
ties.
Replace the dashboard covers.
Table 9: Signal Light Installation
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Can Pressure Input Module (CPIM)
The CPIM is responsible for pro essing the information sent from the pressure sensors.
Accidentally swapping the pressure sensor connections will
not damage the system and can be determined if the display is
showing a negative load.
Do not plug the pressure sensor cable into the far right side
boom cable. This will damage the system.
Step Description Diagram
1. Drill two M8 holes for the CPIM
bracket in the side of the cabin.
Mount using the supplied M8 bolts
and nuts.
2. Connect the cables for the pressure
sensors and boom cable to the CPIM
according to the picture shown.
Connect the supplied M12 4 metre
cable (CB00102 ) into the
connection out of the right side of
the CPIM for the CCIM cable.
Run the CCIM cable towards the
cabin.
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Step Description Diagram
3. Run the height limiter cable from out
the left side of the CPIM to the
hydraulic block behind the cabin.
Connect the tee connector labelled
“Raise” from the height limiter cable
to the boom raise (bottom left)
connector on the hydraulic block and
the tee connector labelled “Extend”
from the height limiter cable to the
boom extend (down second from
right) connector on the hydraulic
block.
Place a single cable tie to hold each
cable position then disconnect the
tee's from the raise and extend
connectors, otherwise the boom will
not move.
Complete the cable installation
during External Cable Completion on
page 21.
Table 10: Can Pressure Input Module (CPIM) Installation
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