eqss Gen-3 LMS Installation Manual
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eqss Gen-3 LMS Installation Manual

Telehandler load management system for jcb 550-80/560-80 agri plus (waste master)
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EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for
JCB 550-80/560-80 Agri Plus (Waste Master)
PLEASE NOTE:
***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***
Failure To Follow Installation Manual Will Void Warranty
VER: 1906171309

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  • Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for JCB 550-80/560-80 Agri Plus (Waste Master) PLEASE NOTE: ***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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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 Covers........................... 6 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...

  • 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: 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: 1906171309 6 of 44...

  • Page 7: 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: 1906171309 7 of 44...

  • Page 8: 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 9: Table 4: Cable Reeler Installation

    Step Description Diagram Connect the supplied M12 10 metre cable (CB001033) 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 10: Cable Reeler Mounting Position

    Cable Reeler Mounting Position Illustration 1: Cable Reeler Mounting Position VER: 1906171309 10 of 44...

  • Page 11: 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 12: Table 5: Main Cylinder Pressure Sensor Installation

    Step Description Diagram 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.

  • Page 13: Compensation Pressure Sensors

    Compensation Pressure Sensors Step Description Diagram 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.

  • Page 14: 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 15: 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 16: Table 8: Forward Camera Installation

    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: 1906171309 16 of 44...

  • Page 17: 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 18: 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 19: 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 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.

  • Page 20: 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 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”...

  • Page 21: External Cable Completion

    External Cable Completion All external cabling is completed in this step. Step Description Diagram Locate the reverse camera, boom and 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 22: 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: 1906171309 22 of 44...

  • Page 23: 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 24: 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 25: 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 26 If the clip-on ferrites were removed from the CCIM and user control cables. See Appendix B: Reattach Ferrites and page 42 for the correct reattachment position. VER: 1906171309 26 of 44...

  • Page 27: 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 28 Follow the appropriate table below depending on if the joystick connection is a 8 or 12 pin connector. EQSS JCB 8 Pin Colour Wire/Colour Direction 2903/Red To Joystick Orange 2903/Red...
  • Page 29 Step Description Diagram Run the two 2 pin tee connectors on the machine cutout harness through the hole leading outside the cabin, run along side the cabin to the hydraulic block located behind the cabin. Connect the tee connector to the boom lower (bottom right) connector on the hydraulic block.

  • Page 30: 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 31: 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 32 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.
  • Page 33 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 34: Table 16: Finalisation

    Table 16: Finalisation Complete the system checklist once installation has been completed. VER: 1906171309 34 of 44...

  • Page 35: 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 36 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 37: Table 17: 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 38: 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 39: Table 18: 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 40: Illustration 2: Damaged Display Connector

    Illustration 2: Damaged Display Connector Do not use any tools to tighten the connector. Illustration 3: Do Not Use Tools To Tighten Connector VER: 1906171309 40 of 44...

  • Page 41: Illustration 4: 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 4: Do Not Over Tighten Nuts Damage to the display connectors is not covered under warranty.

  • Page 42: 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 43: Indexes And Tables

    Indexes and Tables Illustration Index Illustration 1: Cable Reeler Mounting Position............10 Illustration 2: Damaged Display Connector..............40 Illustration 3: Do Not Use Tools To Tighten Connector...........40 Illustration 4: Do Not Over Tighten Nuts..............41 Index of Tables Table 3: Cover removal....................7 Table 4: Cable Reeler Installation................9 Table 5: Main Cylinder Pressure Sensor Installation..........12 Table 6: Compensation Pressure Sensor Installation..........13 Table 7: Reverse Camera Installation................14...
  • Page 44 __________________________________________________________________________________ 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: 1906171309 44 of 44...

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