eqss Gen-3 LMS User manual
EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for JCB 5 0-180
PLEASE NOTE:
VER: 1810171225
***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.
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.
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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provided only for your onvenien e and may be superseded by updates.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
Installation Index...........................................................................................................6
overs.........................................................................................................................10
able Reeler Installation.............................................................................................11
able Reeler Mounting Position.............................................................................13
Pressure Sensor Installation.......................................................................................14
Main ylinder Head Pressure Sensor – Option 1..................................................14
Main ylinder Head Pressure Sensor – Option 2..................................................15
Main ylinder Rod Pressure Sensor......................................................................16
ompensation Pressure Sensors............................................................................18
Reverse amera..........................................................................................................20
Forward amera..........................................................................................................21
Signal Light Installation..............................................................................................22
an Pressure Input Module ( PIM)............................................................................25
an abin Interface Module ( IM)...........................................................................27
External able ompletion.........................................................................................28
Dashboard Switches....................................................................................................29
Display Installation......................................................................................................30
Machine onnections..................................................................................................32
Finalisation..................................................................................................................36
Set Time & Sensor alibration...................................................................................40
Appendix A: Attaching Display onnectors...............................................................43
Appendix B: Reattach Ferrites...................................................................................47
Indexes and Tables.....................................................................................................48
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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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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 Forward amera
7 Reverse amera
8 Light Tower
9 an abin Interface Module ( IM)
10 Display Module
Table 1: Component Installation Index
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olour able Description
Red Boom able
Dark Green Main ylinder Pressure Sensor ables
Brown ompensation Head Pressure Sensor able
Dark Blue ompensation Rod Pressure Sensor able
Light Blue Forward amera able
Violet Signal Light able
Aqua Rear amera able
Dark Purple IM able
Light Green utout Harness
Light Purple Height Limiter able
Orange Display able
Table 2: Cable Installation Index
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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.
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 13.
Mount using the supplied bolts and
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 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.
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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 17mm spacers and M6
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
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Pressure Sensor Installation
The hydrauli pressure sensors are used to measure the lifting load of the telehandler.
Main Cylinder Head Pressure Sensor – Option 1
This will install the pressure sensor into the fixed hydrauli pipe into the head of the
ylinder. This is the re ommend installation method.
Step Description Diagram
1. Modify the main lift cylinder to
install a port hole with a female 9/16
UNF thread into the fixed pipe
connected to the head of the
cylinder as shown.
Note: The boom must be supported
using an A Frame or similar
apparatus. The cylinder may need to
be removed to install the port hole.
2. Install the supplied head pressure
sensor and ensure it is tightly
sealed.
Table 5: Main Head ressure Sensor Installation – Option 1
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Main Cylinder Head Pressure Sensor – Option 2
This will install the main head pressure sensor into the ounterbalan e manifold blo k.
Due to the small clearance around the pressure sensor port,
there is a risk that the fittings may be damaged if the machine
is not operated correctly. If this is a concern use option 1
installation method above instead.
Step Description Diagram
1. Locate port “M1” on the side of the
“Lift” hydraulic manifold and remove
the existing plug. The main head
pressure sensor will be installed in
this location.
Note: The boom must be supported
using an A Frame or similar
apparatus.
2. Make sure that the main head
pressure sensor is tilted up at the
elbow (about 45º) to ensure that the
sensor cable does not hit the
cylinder on the boom down cycle.
Install the supplied head pressure
sensor and ensure it is tightly
sealed.
********** WARNING *********
Ensure that there is enough
clearance between the pressure
sensor and the inner edge of the
machine (as shown in the photo to
the right). If clearance is not
enough for the head pressure
sensor, modify the Main Manifold
Bracket to allow for clearance.
Table 6: Main Head ressure Sensor Installation – Option 2
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Step Description Diagram
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.
Note: The pressure sensor has not
yet been installed in the photo
shown.
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 28.
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 7: Main Rod ressure Sensor Installation
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Compensation Pressure Sensors
Step Description Diagram
1. Undo the hydraulic connection for
the head compensation where the
flexible hydraulic line from the
compensation cylinder is connected
into the fixed hydraulic pipes on the
left side of the boom behind the
cabin.
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
flexible hydraulic line from the
compensation cylinder is connected
into the fixed hydraulic pipes on the
right side of the boom behind the
engine bay.
Install the supplied tee piece and
pressure sensor in line with the
hydraulic connection.
Start the machine, pressurise the
boom and check for leaks.
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Step Description Diagram
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 28.
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 8: Compensation ressure Sensor Installation
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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.
Step Description Diagram
1. Mount the camera to the rear mirror
using the p-clips in the location
shown.
onnect the camera power and
signal connectors to the supplied 5m
camera cable ( B001032).
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
able ompletion on page 28.
Table 9: 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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