eqss Gen-3 LMS User manual
EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for JCB 535- 5 & 533-105
2018 Model
VER: 1906111149
***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.
***Failure To Follow Installation Manual Will Void Warranty***
Documentation Conventions
The list below highlights important do umentation onventions.
VER: 1906111149 2 of 48
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provided only for your onvenien e and may be superseded by updates.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.
VER: 1906111149 3 of 48
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..........................................................................................................18
Forward amera..........................................................................................................20
Signal Light Installation..............................................................................................22
Stabiliser Harness.......................................................................................................24
an Pressure Input Module ( PIM)............................................................................25
External able ompletion.........................................................................................27
an abin Interface Module ( IM)...........................................................................28
Dashboard Switches....................................................................................................29
Display Installation......................................................................................................30
Dashboard ables.......................................................................................................31
Machine onnections..................................................................................................32
Finalisation..................................................................................................................35
Set Time & Sensor alibration...................................................................................39
Appendix A: Attaching Display onnectors...............................................................42
Appendix B: Reattach Ferrites...................................................................................46
Indexes and Tables.....................................................................................................47
VER: 1906111149 4 of 48
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
VER: 1906111149 5 of 48
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 ompensation Pressure Sensors
5 an Pressure Input Module ( PIM)
6 Reverse amera
7 Forward amera
8 Light Tower
9 an abin Interface Module ( IM)
10 Display Module
Table 1: Component Installation Index
VER: 1906111149 6 of 48
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
Table 2: Cable Installation Index
VER: 1906111149 7 of 48
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.
When mounting the cable anchor ensure it is mounted on the
first extendable section not on the last section. If mounted on
the last section the cable reeler will be damaged when the
boom is extended.
Step Description Diagram
1. Drill and tap holes for the cable
reeler according to the mounting
diagram on page 14.
Mount using the supplied bolts.
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 attach
the cable with the supplied M8
washer and the M8 nylock nut.
Note: Ensure the anchor is mounted
on the first extendable section not
on the last section. If mounted on
the last section the cable reeler will
be damaged when the boom is
extended.
VER: 1906111149 12 of 48
Step Description Diagram
3. Drill and tap the M6 holes for the
stow switch trigger. Ensure the stow
switch arm is pressed/switched
when the boom is retracted.
Mount the stow switch trigger using
the supplied bolts.
4. onnect the supplied M12 10 metre
cable ( B001027) into the cable
reeler connection.
able tie to the hydraulic pipes
running underneath the boom then
onto the flexible hydraulic hoses
down to the chassis. Make sure the
cable isn't pinched or stretched
when the boom is raised or lowered.
Table 4: Cable Reeler Installation
VER: 1906111149 13 of 48
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.
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 connects to the rod of the lift
cylinder.
Start the machine, pressurise the
boom and check for leaks.
VER: 1906111149 15 of 48
Step Description Diagram
3. onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
able 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 able ompletion on
page 27.
Ensure the pressure sensors and
cables do not collide with the boom
and chassis structures and the
cables do not stretch or pinch when
the boom is raised and lowered.
Table 5: ressure Sensor Installation
VER: 1906111149 16 of 48
Compensation Pressure Sensors
Step Description Diagram
1. Undo the hydraulic connection for
the head compensation where the
fixed hydraulic pipe from the
compensation cylinder is connected
into the flexible hydraulic line under
the boom.
Install the supplied tee piece and
pressure sensor in line with the
hydraulic connection.
2. Undo the hydraulic connection for
the rod compensation where the
fixed hydraulic pipe from the
compensation cylinder is connected
into the flexible hydraulic line 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. onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
Run the cables along the flexible
hydraulic hoses on the boom down
to the chassis.
Run the cables towards the cabin
and cable tie with the other cables
during External able ompletion on
page 27.
Ensure the pressure sensors and
cables do not collide with the boom
and chassis structures and the
cables do not stretch or pinch when
the boom is raised and lowered.
Table 6: Compensation ressure Sensor Installation
VER: 1906111149 17 of 48
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 and
clearance behind the cover.
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.
VER: 1906111149 18 of 48
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 as shown.
Secure using two M6 nuts.
2. onnect the camera power and
signal connectors to the supplied 5m
camera cable ( B001032).
Note; The white connector is not
used.
Run the cable along the same path
as the headlight cable, run it through
the headlight post, then under the
chassis to the side of the cabin.
able tie with the light tower cable
during External able ompletion on
page 27.
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.
VER: 1906111149 20 of 48
Other manuals for Gen-3 LMS
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