eqss Gen-3 LMS Installation Manual
Telehandler load management system for jcb 541-70 waste master
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Summary of Contents for eqss Gen-3 LMS
- Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for JCB 541-70 Waste Master Failure To Follow Installation Manual Will Void Warranty VER: 20150320...
- 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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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.
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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......................19 Forward Camera......................21 Light Tower Installation....................23 Light Tower Bracket Mounting Position..............24 Can Pressure Input Module (CPIM)................25 External Cable Completion..................27 Can Cabin Interface Module (CCIM)................29 Dashboard Switches....................30... -
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: 20150320 8 of 41... -
Page 9: Illustration 2: Machine Chassis
Illustration 2: Machine Chassis VER: 20150320 9 of 41... -
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 Release the cover beside the joystick VER: 20150320 10 of 41... -
Page 11: Table 3: Cover Removal
Step Description Diagram Remove the side panel next to the cabin under the boom. Remove the covers under the boom. Table 3: Cover removal VER: 20150320 11 of 41... -
Page 12: Cable Reeler Installation
Cable Reeler Installation The cable reeler is used to measure the boom extension to determine the maximum lifting capacity. Step Description Diagram 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. -
Page 13: Table 4: Cable Reeler Installation
Step Description Diagram Connect the supplied M12 10 metre cable (CB001027) into the cable reeler connection. 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. -
Page 14: Cable Reeler Mounting Position
Cable Reeler Mounting Position Illustration 3: Cable Reeler Mounting Position VER: 20150320 14 of 41... -
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 Manifold Installation
Step Description Diagram Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors. Cable 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. -
Page 17: Compensation Pressure Sensors
Compensation Pressure Sensors Step Description Diagram 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. - Page 18 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 VER: 20150320 18 of 41...
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Page 19: 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 20 For further details on running the camera cable refer to the Installation Index on page 6 VER: 20150320 20 of 41...
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Page 21: 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 22 The camera's viewing angle may need to be adjusted once the system is installed and the display is operational. For further details on running the camera cable refer to the Installation Index on page 6 VER: 20150320 22 of 41...
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Page 23: Light Tower Installation
Light Tower Installation The light tower warns other workers when the telehandler is lifting loads close to it's maximum capacity. Step Description Diagram Drill and tap the holes required to mount the light tower bracket on the chassis according to the mounting diagram on page 24. -
Page 24: Light Tower Bracket Mounting Position
Light Tower Bracket Mounting Position Illustration 4: Light Tower Bracket Mounting Position VER: 20150320 24 of 41... -
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: Table 10: Can Pressure Input Module (Cpim) Installation
Step Description Diagram Run the height limiter cable from out the left side of the CPIM to the hydraulic block beside the cabin. Connect the tee connector labelled “Raise” from the height limiter cable to boom raise (top left) connector on the hydraulic block and the tee connector labelled “Extend”... -
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: Table 11: External Cable Completion
Step Description Diagram Secure all the cables from the CPIM and from out the holes into the cabin from the joystick and dashboard. Coil up any additional cable and store under the side panel beside the cabin. Table 11: External Cable Completion VER: 20150320 28 of 41... -
Page 29: 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 light tower cables to the M12 connectors on the CCIM. Note: It doesn't matter which of the M12 connectors the CCIM and light tower cables are plugged into. -
Page 30: Dashboard Switches
Dashboard Switches The user input 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 input control dial in the dashboard, aligned so the Enter cap is facing up. -
Page 31: 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 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 Connect the spade terminals on the green and yellow wires from the machine input harness with the 4 and 12 pin connectors into the override switch mounted in the dashboard. - Page 33 Step Description Diagram Run the snake tube with the red and white wires on the machine input harness through the hole leading outside the cabin and then through the hole leading back inside the cabin underneath the joystick. Locate the 8 pin connector from the joystick and splice into the matching wire colours from the machine input harness.
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Page 34: Table 15: Machine Connections
Step Description Diagram Attach the radio power harness to the radio connector. Note: If the radio connector is not installed in the machine. Cut off the tee connectors from the radio power harness and splice into the 4 pin radio power connector located under the dashboard according to the table below. -
Page 35: Finalisation
Finalisation This section will complete the final power connections to power the system and finish any additional items. Do not disconnect the camera power connection while the system is operating as this can damage the fuse. Step Description Diagram Connect the 4, 6 and 12 pin connectors from the machine input and cutout harnesses into the I/O harness. - Page 36 Step Description Diagram 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. Reconnect the tee connectors back into the hydraulic block.
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Page 37: Table 16: Finalisation
Step Description Diagram 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. Set the machine into reverse gear to activate the reverse camera. Adjust the reverse camera so the video is level. -
Page 38: Sensor Calibration
Sensor Calibration Once the installation is complete, 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 Description... -
Page 39: Table 17: Sensor Calibration
Step Description Diagram Enter the password (Default Password: 2-8-4) 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. Table 17: Sensor Calibration VER: 20150320 39 of 41... -
Page 40: 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: Light Tower Bracket Mounting Position..........24 Index of Tables Table 1: Component Installation Index................6 Table 2: Cable Installation Index..................7 Table 3: Cover removal....................11 Table 4: Cable Reeler Installation................13 Table 5: Pressure Manifold Installation..............16 Table 6: Compensation Pressure Sensor Installation..........17... - Page 41 __________________________________________________________________________________ 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: 20150320 41 of 41...
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