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eqss Gen-3 LMS Installation Manual

Telehandler load management system for jcb 535-95 & 533-105 2018 model
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EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for JCB 535-95 & 533-105
2018 Model
***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***
VER: 1906111149

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  • Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for JCB 535-95 & 533-105 2018 Model ***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.
  • Page 2 Documentation Conventions The list below highlights important documentation conventions. 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.
  • Page 3 Important Information Information contained in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates. It is your responsibility to ensure that the application or our equipment meets with your specifications.

  • Page 4: Table Of Contents

    Table of Contents Tools Required for Installation..................5 Installation Index......................6 Covers.........................10 Cable Reeler Installation.....................12 Cable Reeler Mounting Position................14 Pressure Sensor Installation..................15 Main Cylinder Pressure Sensors................15 Compensation Pressure Sensors................17 Reverse Camera......................18 Forward Camera......................20 Signal Light Installation....................22 Stabiliser Harness.......................24 Can Pressure Input Module (CPIM)................25 External Cable Completion..................27 Can Cabin Interface Module (CCIM)................28 Dashboard Switches....................29...

  • Page 5: Tools Required For Installation

    Tools Required for Installation The tools required to perform the installation of the TSS are listed below Pencil or Texta • Drill • Drill bits • 3.3 mm ◦ 4.5 mm ◦ 5 mm ◦ 6.25 mm ◦ 6.8 mm ◦...

  • Page 6: Installation Index

    Installation Index The components and cables of the Gen-3 Telehandler Load Management System are outline in the tables below. The following pages show where the components are installed and the cable routing. See the appropriate manual section for a detailed installation description for each component.

  • Page 7: Table 2: Cable Installation Index

    Colour Cable Description Boom Cable Dark Green Main Cylinder Head Pressure Sensor Cable Brown Main Cylinder Rod Pressure Sensor Cable Dark Blue Compensation Cylinder Pressure Sensors Cables Light Blue Forward Camera Cable Violet Light Tower Cable Aqua Rear Camera Cable Dark Purple CCIM Cable Light Green Cutout Harness...

  • Page 8: Illustration 1: Machine Boom

    Illustration 1: Machine Boom VER: 1906111149 8 of 48...

  • Page 9: Illustration 2: Machine Chassis

    Illustration 2: Machine Chassis VER: 1906111149 9 of 48...

  • Page 10: Covers

    Covers Remove the following covers before starting the installation Step Description Diagram Release the dashboard display bolts Remove the indicator display behind the steering wheel Remove the cover on the side of the cabin. VER: 1906111149 10 of 48...

  • Page 11: Table 3: Cover Removal

    Step Description Diagram Remove the cover for the hydraulics behind the cabin Table 3: Cover removal VER: 1906111149 11 of 48...

  • Page 12: Cable Reeler Installation

    Cable Reeler Installation The cable reeler is used to measure the boom extension to determine the maximum lifting capacity. 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.

  • Page 13: Table 4: Cable Reeler Installation

    Step Description Diagram 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. Connect the supplied M12 10 metre cable (CB001027) into the cable reeler connection.

  • Page 14: Cable Reeler Mounting Position

    Cable Reeler Mounting Position Illustration 3: Cable Reeler Mounting Position VER: 1906111149 14 of 48...

  • Page 15: Pressure Sensor Installation

    Pressure Sensor Installation The hydraulic pressure sensors are used to measure the lifting load of the telehandler. Main Cylinder Pressure Sensors Step Description Diagram 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.

  • Page 16: Table 5: Pressure Sensor Installation

    Step Description Diagram Connect the supplied M12 4 metre cables (CB001026) 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.

  • Page 17: Compensation Pressure Sensors

    Compensation Pressure Sensors Step Description Diagram 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.

  • Page 18: Reverse Camera

    Reverse Camera The rear camera video is displayed on the screen when the machine 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...
  • Page 19 For further details on running the camera cable refer to the Installation Index on page 6 VER: 1906111149 19 of 48...

  • Page 20: Forward Camera

    Forward Camera The forward camera video is displayed on the screen when the machine is in forward gear to allow the operator to see past the boom to obstructions 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.
  • Page 21 For further details on running the camera cable refer to the Installation Index on page 6 VER: 1906111149 21 of 48...

  • Page 22: Signal Light Installation

    Signal Light Installation The signal light warns other workers when the telehandler is lifting loads close to it's maximum capacity. Ensure the power supply voltage is greater than 13.5V otherwise the signal light may not illuminate correctly. Step Description Diagram Remove the magnet from the bottom of the signal light mounting bracket and flip the signal light mounting...

  • Page 23: Table 9: Signal Light Installation

    Step Description Diagram 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.

  • Page 24: Stabiliser Harness

    Stabiliser Harness The stabiliser indicate to the Gen3 system when the machine has greater stability and adjusts the rated capacity accordingly. Step Description Diagram The stabiliser harness is made of two wires; green and blue, with one side containing female connector pins and the other side bare, contained inside of snake tube.

  • Page 25: Can Pressure Input Module (Cpim)

    Can Pressure Input Module (CPIM) The CPIM is responsible for processing the information sent from the pressure sensors. Accidentally swapping the pressure sensor connections will not damage 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.
  • Page 26 For further details on running the cables refer to the Installation Index on page 6 VER: 1906111149 26 of 48...

  • Page 27: External Cable Completion

    External Cable Completion All external cabling is completed in this step. Step Description Diagram Locate the reverse camera, boom and compensation pressure cables at the rear of the machine and cable tie to the existing snake tube and hydraulic lines running towards and underneath the cabin.

  • Page 28: Can Cabin Interface Module (Ccim)

    Can Cabin Interface Module (CCIM) The CCIM connects the system into the machine electronics. Step Description Diagram Connect the CCIM and signal light cables to the M12 connectors on the CCIM. Note: It doesn't matter which of the M12 connectors the CCIM and signal light cables are plugged into.

  • Page 29: Dashboard Switches

    Dashboard Switches The user control and override switch are installed in the dashboard. Step Description Diagram Remove a blanking switch plate from the dashboard and install the override switch. Drill a 34 mm hole into the dashboard. Install the user control in the dashboard, aligned so the Enter cap is facing up.

  • Page 30: Display Installation

    Display Installation The display shows the current safety status of the telehandler. Step Description Diagram Position the display bracket in the top right of the dashboard in the approximate location shown. Drill two 7 mm holes to attach the bracket to the dashboard. Secure the bracket to the dashboard using the supplied large washers and nuts...

  • Page 31: Dashboard Cables

    Dashboard Cables The dashboard cables connects the display and the machine connections to the Gen 3 system. Step Description Diagram Run the 5 pin user control cable and the 8 pin cable from the CCIM through the gap between the window and the dashboard.

  • Page 32: Machine Connections

    Machine Connections The following procedures connect the safety systems to the existing electronics in the machine. Isolate the main battery before starting the machine connections Step Description Diagram On the front of the machine, remove the hydraulic covers on the two stabilisers. Locate the 4 pin connector for the left stabiliser pressure sensor and splice the green wire from the...
  • Page 33 Step Description Diagram Splice the following wire colours from the machine input harness with the 4 pin connector into the connector for the left steering column switch (marked with red tape). Note: Remove the steering wheel height adjustment lever, to move the steering wheel higher, to get better access to the switch connector...

  • Page 34: Table 17: Machine Connections

    Step Description Diagram Connect the tee connectors from the machine cutout harness into the bottom solenoid connector shown. Disconnect the tee connector from the solenoid, to allow for complete boom function until the installation is completed in the section Finalisation. Attach the radio power harness to the radio connector.

  • Page 35: Finalisation

    Finalisation This section will complete the final power connections to power the system and finish any additional items. Step Description Diagram Connect the spade terminals from the machine input harness into the override switch Connect the 4 pin connector from the machine input harness into the I/O harness.
  • Page 36 Step Description Diagram Connect the 3 pin connector into the Power/Camera harness. Connect the spade lug on the black wire to the negative (black) battery terminal. Connect the spade lug on the blue wire to the positive (red) battery terminal. Coil up the extra cables and store underneath the dashboard cover.
  • Page 37 Step Description Diagram Reconnect the main battery from the isolation switch. Turn the machine onto first stage /accessories and ensure the system is activated. Adjust the display bracket for optimal viewing Set the machine into forward gear to activate the forward camera. Adjust the forward camera so the front right wheel is visible.

  • Page 38: Table 18: Finalisation

    Table 18: Finalisation Complete the system checklist once installation has been completed. VER: 1906111149 38 of 48...

  • Page 39: Set Time & Sensor Calibration

    Set Time & Sensor Calibration Once the installation is complete, the time will need to be set and the sensors will require calibration. A sensor calibration must be performed once the cable reeler and CPIM have been mounted. If the cable reeler or CPIM have been moved/repositioned a recalibration must be performed Step...
  • Page 40 Step Description Diagram Enter the password (Default Password: 2-8-4) Select Set Time / Date Enter the correct time and date for your area. Press the arrow keys to select a time/date parameter Press Enter and the parameter will change to red, press the arrow keys to change the value and then press the Enter key to store the value.

  • Page 41: Table 19: Sensor Calibration

    Step Description Diagram Scroll to the next page and select Save to store the new time/date and return to the Advanced Menu. Select Sensor Calibrations Select Calibrate Carrier Angle and then follow the instructions on the screen to complete the calibration. Repeat for Calibrate Boom Angle and Calibrate Boom Length.

  • Page 42: Appendix A: Attaching Display Connectors

    Appendix A: Attaching Display Connectors The procedure below describes the correct method of attaching the cables to the screw lock connectors on the display. If the M12 screw lock connectors on the display are over tightened, it will twist the connector pins attaching the connector to the PCB.

  • Page 43: Table 20: Install Display Connector Procedure

    Step Description Diagram Push the female connector from the cable into the male connector on the display. Rotate the nut on the female connector by hand in a clockwise direction, until the tension on the nut starts to increase. Push the cable in again and repeat steps 3 and 4 until the connector is secure.

  • Page 44: Illustration 4: Damaged Display Connector

    Illustration 4: Damaged Display Connector Do not use any tools to tighten the connector. Illustration 5: Do Not Use Tools To Tighten Connector VER: 1906111149 44 of 48...

  • Page 45: Illustration 6: Do Not Over Tighten Nuts

    Do not over-tighten the nuts on the back of the display connectors. These nuts should only be hand tightened. If the nuts are overtightened it will damage the PCB inside the display. Illustration 6: Do Not Over Tighten Nuts Damage to the display connectors is not covered under warranty.

  • Page 46: Appendix B: Reattach Ferrites

    Appendix B: Reattach Ferrites If the clip-on ferrites on the displays are removed during installation, they will need to be reattached as shown in the procedure below. If the ferrites are not reinstalled or attached in the specified location the Gen3-LMS kit will not meet the AS/NZS CISPR 22:2006 certification.

  • Page 47: Indexes And Tables

    Indexes and Tables Illustration Index Illustration 1: Machine Boom..................8 Illustration 2: Machine Chassis..................9 Illustration 3: Cable Reeler Mounting Position............14 Illustration 4: Damaged Display Connector..............44 Illustration 5: Do Not Use Tools To Tighten Connector...........44 Illustration 6: Do Not Over Tighten Nuts..............45 Index of Tables Table 1: Component Installation Index................6 Table 2: Cable Installation Index..................7...
  • Page 48 __________________________________________________________________________________ Equipment Safety Systems Pty. Ltd. Tel: +61 3 8770 6555 ABN: 31 061 789 151 27 Cumberland Drive, Seaford 3198, Victoria, Australia Fax: +61 3 8770 6590 Web: www.eqss.com.au VER: 1906111149 48 of 48...

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