eqss Gen-3 LMS Installation Manual
Telehandler load management system for jcb 540-200
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- Installation manual (40 pages)
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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 540-200 Failure To Follow Installation Manual Will Void Warranty VER: 20140527...
- 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in this publication regarding this devices applications and the like is provided only for your convenience and may be superseded by updates.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 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 Light Tower Installation....................16 Can Pressure Input Module (CPIM)................17 Cutout Harness......................19 Can Cabin Interface Module (CCIM)................20 External Cable Completion..................21 Dashboard Switches....................22... -
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 Remove the bar in front of the fuse panel Remove the fuse/relay panel cover inside the cabin Release the dashboard display bolts VER: 20140527 6 of 32... -
Page 7: Table 3: Cover Removal
Step Description Diagram Remove the indicator display behind the steering wheel Remove the outer cover beside the cabin Table 3: Cover removal VER: 20140527 7 of 32... -
Page 8: 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 holes for the cable reeler according to the mounting diagram on page 10. Mount using the supplied bolts. Drill and tap an M8 hole for the cable anchor. -
Page 9: Table 4: Cable Reeler Installation
Step Description Diagram Connect the supplied M12 10 metre cable (CB001027) into the cable reeler connection. Cable 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. -
Page 10: Cable Reeler Mounting Position
Cable Reeler Mounting Position Illustration 1: Cable Reeler Mounting Position VER: 20140527 10 of 32... -
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: Pressure Sensor 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 13: Compensation Pressure Sensors
Compensation Pressure Sensors Step Description Diagram Undo the hydraulic connection for the head compensation into the flexible hydraulic line on the left compensation cylinder. Install the supplied tee piece and pressure sensor in line with the hydraulic connection. View from under the boom Undo the hydraulic connection for the rod compensation into the flexible hydraulic line on the right... -
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. Step Description Diagram Drill a 31mm hole in the location shown. Making sure to leave enough room for a license plate Insert the camera through the hole and adjust the angle using the... -
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. Step Description Diagram Mount the camera to the side mirror using the p-clips in the location shown. -
Page 16: 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 two diagonal M6 holes required to mount the light tower bracket to the left of the headlight post as shown. -
Page 17: 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 18: 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 rear of the machine to the hydraulic block. Connect the tee connector labelled Raise from the height limiter cable to the raise pilot connector on the spool control block and the tee connector labelled Extend from the height limiter cable to the extend... -
Page 19: Cutout Harness
Cutout Harness Step Description Diagram Connect the tee connector labelled Lower from the cutout harness to the lower pilot connector on the spool control block. Place a single cable tie to hold the cable's position then disconnect the tee's from lower pilot connector, otherwise the boom will not move. -
Page 20: 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 cable from the CPIM to the M12 bulkhead connector on the CCIM. Connect the Power/Camera and IO Harnesses to the bulkhead connectors on the CCIM. -
Page 21: External Cable Completion
External Cable Completion All external cabling is completed in this step. Step Description Diagram Locate the reverse camera, cutout, boom and pressure sensor 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: 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 23: 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 24: 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 Splice the following wire colours from the cable with the 2 pin connector into connector J2 behind the dashboard for the stabiliser signals. -
Page 25: Table 16: 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 26: Finalisation
Finalisation This section will complete the final power connections to power the system and finish any additional items. Step Description Diagram Connect the 2, 4, 6 and 8 pin connectors into the I/O harness. Connect the 3 pin connector into the Power/Camera harness. - Page 27 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 under the boom.
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Page 28: Table 17: 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 29: 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 30: Table 18: 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 18: Sensor Calibration VER: 20140527 30 of 32... -
Page 31: Indexes And Tables
Indexes and Tables Illustration Index Illustration 1: Cable Reeler Mounting Position............10 Index of Tables Table 3: Cover removal....................7 Table 4: Cable Reeler Installation................9 Table 5: Pressure Sensor Installation................12 Table 6: Compensation Pressure Sensor Installation..........13 Table 7: Reverse Camera Installation................14 Table 8: Forward Camera Installation................15 Table 9: Light Tower Installation................16 Table 10: Can Pressure Input Module (CPIM) Installation........18 Table 11: Cutout Harness Installation................19... - Page 32 __________________________________________________________________________________ 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: 20140527 32 of 32...
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