eqss Gen-3 LMS Installation Manual

eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for JCB 541-70 CS PLEASE NOTE: VER: 1607211119 ***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.

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. VER: 1607211119 2 of 40

provided only for your convenience and may be superseded by updates.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. 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 disclaims all liability arising from this information and its use. Use of Equipment Safety Systems’ products as critical components in life support systems is not authorised except with express written approval by Equipment Safety Systems. No licenses are conveyed, implicitly or otherwise, under any Equipment Safety Systems intellectual property rights. VER: 1607211119 3 of 40

Tools Required for Installation.....................................................................................5 Covers...........................................................................................................................6 Cable Reeler Installation...............................................................................................7 Cable Reeler Mounting Position...............................................................................9 Pressure Sensor Installation.......................................................................................10 Main Cylinder Pressure Sensors............................................................................10 Compensation Pressure Sensors............................................................................12 Reverse Camera..........................................................................................................14 Forward Camera..........................................................................................................15 Signal Light Installation..............................................................................................17 With Windshield Guard Bar.....................................................................................17 Without Windshield Guard Bar................................................................................18 Can Pressure Input Module (CPIM)............................................................................20 External Cable Completion.........................................................................................21 Can Cabin Interface Module (CCIM)...........................................................................23 Dashboard Switches....................................................................................................24 Display Installation......................................................................................................25 Machine Connections..................................................................................................26 Finalisation..................................................................................................................29 Set Time & Sensor Calibration...................................................................................32 Appendix A: Attaching Display Connectors...............................................................35 Indexes and Tables.....................................................................................................39 VER: 1607211119 4 of 40

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 ◦ 8.5 mm • Centre punch • Tap T-Handle • Taps ◦ M6 ◦ M7 x 0.75 ◦ M8 • Drill and tap oil • Metric Allen keys • Phillips Head screw driver • Spanners and sockets ◦ 7 mm ◦ 10 mm ◦ 13 mm • Locktite thread locker • Side cutters • Stanely knife • Crimpers • Wire strippers VER: 1607211119 5 of 40

Step Description Diagram 1. Release the dashboard display bolts 2. Remove the indicator display behind the steering wheel 3. Remove the cover for the hydraulics behind the cabin Table 1: Cover removal VER: 1607211119 6 of 40

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. Ensure the stow switch arm is correctly adjusted to prevent this error. Step Description Diagram 1. Drill and tap the holes for the cable reeler according to the mounting diagram on page 9. Mount using the supplied M6 x 12 mm bolts and washers. 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 secure the cable to the anchor. 3. Drill and tap the M6 holes for the stow switch trigger. Ensure the stow switch is pressed when the boom is retracted. Mount the stow switch trigger using the supplied M6 x 30 mm bolts and 17 mm standoffs. VER: 1607211119 7 of 40

cable (CB001027) into the cable reeler connection. 5. 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. Make sure the cable isn't pinched or stretched when the boom is raised or lowered. Run the cable towards the cabin and cable tie with the other cables during External Cable Completion on page 21. Table 2: Cable Reeler Installation VER: 1607211119 8 of 40

Illustration 1: Cable Reeler Mounting Position VER: 1607211119 9 of 40

The hydraulic pressure sensors are used to measure the lifting load of the telehandler. Main Cylinder Pressure Sensors Step Description Diagram 1. 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. Apply the handbrake and insert chock under wheels. Release the blanking cap on the hydraulic tee. Removing the blanking cap will release the hydraulic pressure which may result in a spray of oil. Install the supplied pressure sensor and ensure it is tightly sealed. 2. Install the tee connector and pressure sensor into the rod of the main lift cylinder, where the flexible hose is connected to the solid hose on the chassis under the lift cylinder. Start the machine, pressurise the boom and check for leaks. View from under the main lift cylinder VER: 1607211119 10 of 40

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. Run the cables towards the cabin and cable tie with the other cables during External Cable Completion on page 21. Table 3: Pressure Manifold Installation VER: 1607211119 11 of 40

Step Description Diagram 1. 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. 2. Undo the hydraulic connection for the rod 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 Start the machine, pressurise the boom and check for leaks. 3. Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors. Add both cables to 2 m of snake tube. Run the snake tube and cables towards the cabin and cable tie with the other cables during External Cable Completion on page 21. Table 4: Compensation Pressure Sensor Installation VER: 1607211119 12 of 40

and pressure sensor do not hit the boom when the boom is lowered VER: 1607211119 13 of 40

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 1. 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 alignment washers. 2. Connect the camera power and signal connectors to the supplied 5m camera cable (CB001032). Note; The white connector is not used. Secure the camera cable to the license plate light cables Run the remainder of the cable towards the cabin and cable tie with the other cables during External Cable Completion on page 21. Table 5: Reverse Camera Installation The camera's viewing angle may need to be adjusted once the system is installed and the display is operational. VER: 1607211119 14 of 40

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. Step Description Diagram 1. Mount the camera to the side mirror using the p-clips as shown. Secure using two M6 nuts. 2. Connect the camera power and signal connectors to the supplied 5m camera cable (CB001032). Note; The white connector is not used. Run the cable along the same path as the headlight cable, run it through the headlight post, then under the chassis to the side of the cabin. Cable tie during External Cable Completion on page 21. Table 6: Forward Camera Installation VER: 1607211119 15 of 40

system is installed and the display is operational. VER: 1607211119 16 of 40

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. With Windshield Guard Bar Step Description Diagram 1. Mount the signal light to the top of the front windshield guard on the cabin. 2. Run the cable down the side of the windshield and cable tie to the windshield guard bar down towards the chassis. Table 7: Signal Light Installation With Windshield Guard Bar VER: 1607211119 17 of 40

Step Description Diagram 1. Remove the magnet from the bottom of the signal light mounting bracket and flip the signal light mounting bracket so the mounting holes are on the bottom. Cut and remove 2.6 m of snake tube from the end of the cable starting at the signal light. Drill two M4 holes to mount the signal light bracket to the left headlight support bracket on the roof. Mount using the supplied M4 bolts and nuts. 2. Run the cable along the top of the roof to towards the right headlight support bracket. Drill a single M6 hole to mount a metal p-clip. Attach the cable to metal p-clip and secure using the supplied M6 bolt and nut. 3. Run the cable down between the edge of the windshield and cabin frame to the base of the windshield. Use a water proof adhesive to ensure the cable will remain within the gap between the edge of the windshield and cabin frame. VER: 1607211119 18 of 40

a cable tie. Note: Make sure the cable is securely tensioned, so it doesn't move out of the groove between the edge of the windshield and cabin frame. Table 8: Signal Light Installation Without Windshield Guard Bar VER: 1607211119 19 of 40

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. This will damage the system. Step Description Diagram 1. Drill and tap two M8 holes for the CPIM bracket in the chassis behind the cabin. Mount using the supplied M8 x 12mm bolts and washers. 2. Connect the cables for the pressure sensors and boom cable to the CPIM according to the picture shown. Connect the supplied M12 4 metre cable (CB001026) into the connection out of the right side of the CPIM for the CCIM cable. Run the CCIM cable towards the cabin. Table 9: Can Pressure Input Module (CPIM) Installation VER: 1607211119 20 of 40

All external cabling is completed in this step. Step Description Diagram 1. 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. Coil up any additional cable and store under the side panel beside the cabin. View from under the boom towards the rear of the machine 2. At the front of the machine cable tie the front camera cable to the side of the cabin. Note: The old light tower is shown 3. Run the CCIM, signal light and camera cables through the hole into the cabin VER: 1607211119 21 of 40

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 10: External Cable Completion VER: 1607211119 22 of 40

The CCIM connects the system into the machine electronics. Step Description Diagram 1. 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. 2. Connect the Power/Camera and IO Harnesses to the bulkhead connectors on the CCIM. Position the CCIM underneath the dashboard using double sided velcro tape. Note: Make sure to leave enough room for the connectors and that the dashboard displays can be reinstalled. 3. Install the backup battery behind the indicator display using double sided velcro tape. Table 11: CCIM Installation VER: 1607211119 23 of 40

Step Description Diagram 1. Remove a blanking switch plate from the dashboard and install the override switch. 2. 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. Table 12: Dashboard Switches Installation VER: 1607211119 24 of 40

Step Description Diagram 1. 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 Attach the display to the bracket and tighten the grub screw Table 13: Display Installation Adjust the display bracket for optimal viewing angle once the display is powered VER: 1607211119 25 of 40

machine. Isolate the main battery before starting the machine connections Step Description Diagram 1. 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 Wire Colour Wire Number Orange 809 Red 808 2. Connect the spade terminals from the machine input harness to the override switch VER: 1607211119 26 of 40

the cabin. Run the machine cutout harness from underneath the dashboard down to the hydraulic block. 4. Attach the supplied 2 pin connectors to the machine cutout harness according to the table below. Wire Colour Pin Number Black Male - 1 Violet Male - 2 Blue Female - 1 Violet Female - 2 5. 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. VER: 1607211119 27 of 40

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. Wire Colour Wire Number Black 601AG Violet 181 Yellow 301F Table 14: Machine Connections VER: 1607211119 28 of 40

additional items. Do not disconnect the camera power connection while the system is operating as this can damage the fuse. Step Description Diagram 1. Connect the 4, 6 and 12 pin connectors from the machine input and cutout harnesses into the I/O harness. 2. Connect the camera power and signal cables from the front and rear cameras to the power/camera harness connectors. Note: The white connector is not used. 3. Connect the 3 pin connector from the radio power harness into the power/camera harness. VER: 1607211119 29 of 40

black wire to the negative (black) battery terminal. Connect the spade lug on the blue wire to the positive (red) battery terminal. 5. Coil up the extra cables and store underneath the dashboard cover. 6. Reconnect the tee connector back into the hydraulic block behind the cabin. 7. Reconnect the main battery from the isolation switch. Turn the machine onto first stage /accessories and ensure the system is activated. VER: 1607211119 30 of 40

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. 9. Perform a final check on all the cabling and sensors. Replace all the covers Table 15: Finalisation Complete the system checklist once installation has been completed. VER: 1607211119 31 of 40

Once the installation is complete, the time will need to be set and the sensors will require calibration. Step Description Diagram 1. Press Enter on the user control dial to enter the menu system. Press the arrow buttons to select System Menu. Press Enter to select the menu. 2. Select Advanced Menu VER: 1607211119 32 of 40 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

(Default Password: 2-8-4) 4. Select Set Time / Date 5. 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. Note: The hour parameter is in 24 hour clock Repeat for the rest of the time values VER: 1607211119 33 of 40

Save to store the new time/date and return to the Advanced Menu. 7. Select Sensor Calibrations 8. 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 16: Sensor Calibration VER: 1607211119 34 of 40

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. Step Description Diagram 1. Connect the cable from the user control to the top 5 pin connector on the display. Connect the cable from the CCIM to the bottom 8 pin connector on the display. 2. Line up the alignment hole on the cable connector with the alignment notch on the display connector. VER: 1607211119 35 of 40

cable into the male connector on the display. 4. Rotate the nut on the female connector by hand in a clockwise direction, until the tension on the nut starts to increase. 5. Push the cable in again and repeat steps 3 and 4 until the connector is secure. Table 17: Install Display Connector Procedure The method to correctly secure the cable is to push-twist- push-twist until the connector is fully inserted and secure. This will minimise the twisting force applied to the connector. Below is a picture of a damaged connector on the PCB inside the display. This damaged occurred because the connector was over tightened. VER: 1607211119 36 of 40

Do not use any tools to tighten the connector. Illustration 3: Do Not Use Tools To Tighten Connector VER: 1607211119 37 of 40

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. VER: 1607211119 38 of 40

Illustration Index Illustration 1: Cable Reeler Mounting Position............................................................9 Illustration 2: Damaged Display Connector................................................................37 Illustration 3: Do Not Use Tools To Tighten Connector...........................................37 Illustration 4: Do Not Over Tighten Nuts...................................................................38 Index of Tables Table 1: Cover removal................................................................................................6 Table 2: Cable Reeler Installation................................................................................8 Table 3: Pressure Manifold Installation.....................................................................11 Table 4: Compensation Pressure Sensor Installation................................................12 Table 5: Reverse Camera Installation........................................................................14 Table 6: Forward Camera Installation........................................................................15 Table 7: Signal Light Installation With Windshield Guard Bar..................................17 Table 8: Signal Light Installation Without Windshield Guard Bar.............................19 Table 9: Can Pressure Input Module (CPIM) Installation..........................................20 Table 10: External Cable Completion........................................................................22 Table 11: CCIM Installation........................................................................................23 Table 12: Dashboard Switches Installation................................................................24 Table 13: Display Installation.....................................................................................25 Table 14: Machine Connections.................................................................................28 Table 15: Finalisation.................................................................................................31 Table 16: Sensor Calibration......................................................................................34 Table 17: Install Display Connector Procedure.........................................................36 VER: 1607211119 39 of 40

Tel: +61 3 8770 6555 27 Cumberland Drive, Seaford 3198, Victoria, Australia Fax: +61 3 8770 6590 Web: www.eqss.com.au VER: 1607211119 40 of 40