Gen3 - Installation - System Test
The components now need to be tested to ensure
everything has been properly installed and is functioning correctly.
Power the system from the machine's ignition key switch. After about 10 seconds, the
display will load with the boot screen and then it will load the main screen. If the screen does not load, check the power connections.
Some machines have an economy mode that switches off the
accessories after a while (if the engine is not active). Turn the
engine on to ensure the Gen3 LMS remains powered while
testing.
Once the main screen has loaded, navigate to the on screen 'Diagnostics Menu'. Press the
user control center 'Enter' switch to enter the menu system. Press the up/down left/right arrow keys to highlight a menu option and
press the Enter to select the option.
Select the following menu options to access the
diagnostics screen [System Menu] → [Diagnostics Menu]
The diagnostics menu is displayed across multiple pages, scroll up and down using the user control switches to access the different pages
The diagnostics menu displays the raw sensor values (as well as the switch states for the Gen3 LMS
system) and verifies that all sensors and switch inputs are operating correctly.
The first items displayed on the diagnostics menu are the main pressure sensor values.
This is the raw reading from the pressure sensors installed in the main lift cylinder (the
values are between 0 – 4096).
Raise the boom by about 5 degrees and note the main head and main rod pressure
sensor values. The main rod value should be a small number and may be 0. The main
head value may drop down initially after the lift is completed, and after about 10 seconds
the pressure reading should start to stabilize at a constant value.
Leave the system
running for about 5 minutes and check that the main head pressure reading has not
changed. If the reading has dropped and continues to drop; this may indicate that the head
pressure sensor has been installed on the head inlet hose instead of between the
counterbalance valve and the head of the cylinder (see section Pressure Sensor
Installation to install the head pressure sensor in the correct location).
If the main head pressure reading is holding, lower the boom by about 5 degrees. The
main rod value should have increased dramatically compared to when the boom was
raised. If the main rod value has not increased, this could indicate that the rod pressure
sensor has not been installed in the correct location. The main head value should have
also increased in response to the increase in the main rod pressure.
If the main head
value has not increased compared to when the boom was raised, this could indicate that
the head pressure sensor has not been installed in the correct location.
Since the hydraulic oil in the rod of the cylinder is not locked behind the counterbalance
valve, the rod pressure value will start to immediately decrease after the boom lower action
is completed. This loss of hydraulic pressure from the rod of the cylinder will start to relieve
the pressure on the head of the cylinder - resulting in a decrease of the head pressure
value as well.
The boom angle value displays the raw boom angle in 0.1 degree units. Note the current
boom angle value, then raise the boom. The boom angle reading should increase. If the
value decreases, then the cable reeler was mounted upside down and must be mounted
with the stow switch and connector at the bottom, (see section Cable Reeler
Installation to remount the cable reeler).
The carrier angle values display the raw carrier angles for both the X and Y axes in 0.1
degree units. Both carrier angle values should be close to 0 and can be negative. If either
of the values is greater than ± 50 (5 degrees), then the CPIM will need to be remounted. The X
and Y axes map to the longitudinal and lateral axes of the carrier - depending on the CPIM
mounting orientation. Note the reading of both the X and Y carrier angle values, then tilt the
machine over to the left by driving on the side of a curb or by using the lateral leveling function. Either the X or Y carrier angle values will change.
If the X value has changed
then the X axis is the lateral carrier axis and the Y axis is the longitudinal carrier axis. If the
Y value has changed then the Y axis is the lateral carrier axis and the X axis is the
longitudinal carrier axis. Return the lateral carrier axis back to a level position and tilt the
carrier backward by either driving up a hill or by lowering the stabilizers, the other
longitudinal axis value will change.
The boom length value displays the boom length pulse count reading (internal electronics calculate boom length by counting pulses as the boom telescopes). Fully retract the
boom, the value should be 500 when the boom is stowed (fully retracted). If the value is
not 500, then the boom stow switch is not being triggered correctly and will need to be
adjusted. Extend the boom and the boom length value will increase. Retract the boom angle
the boom length value will decrease - until the boom is stowed and the value will read 500.
The remaining display items in the diagnostics menu are digital input on/off signals. If the
input signal is inverted (e.g. The forward gear signal shows inactive when the machine is in
forward gear and shows active when the machine is in neutral) the signal polarity can be
changed. The forward and reverse gear signal values will be active when in the respective gear.
Place the machine into forward gear; the forward gear signal will be active and the reverse
gear signal will be inactive. Place the machine into reverse gear; the reverse gear signal
will be active and the forward gear signal will be inactive. If the respective gear signals do
not switch to active and the signal is not inverted, then either the signal line has not been
connected correctly, or the DIP switch settings (in the CCIM) need to be changed/reversed.
We don't recommend end users changing the DIP switch settings without being directed by EQSS technical staff. DIP switches are set at the EQSS factory per order - for specific machines prior to shipping to customers.
Some installations have diodes in the forward/reverse gear signal path and may need to be reversed for correct logic.
The override signal will be active when the override switch is triggered. Press the override
switch and the override signal will be active. If the override signal does not switch to active, then either the signal line has not been connected correctly or the diode polarity needs to
be reversed.
The left and right stabilizer down signal values will be active when the respective stabilizer
has been lowered (unless the signal is inverted). Depending on how the stabilizer switches
have been installed, both the left and right stabilizers may need to be fully lowered for both
signal values to change to active. If limit switches were installed and both stabilizers are
fully lowered, then the switch arm may need to be adjusted.
Return from the diagnostics menu and enter the system tests menu.
The system tests menu tests the outputs from the Gen3 LMS system. To engage a system
test, highlight the desired test from the menu. Press the user control dial and the highlight
will change color indicating that the test output is currently active. Press the user control
dial again to end the test and return to normal function.
The first test is the primary cutout. When this test is engaged, the hydraulic cutout is
activated. Ensure the boom can only be raised and retracted if an aggravated movement
cutout is fitted, or that all boom functions are disabled (if a full cutout is fitted). If the cutout is
inverted (meaning the cutout is active when the test is not engaged) under normal operation
when the test is engaged - the signal polarity should be changed. If the cutout signal is inverted, the Gen3 LMS will produce a
cutout for the first 10 seconds after startup while the system is loading. Some machine
electronics perform a test at startup on the cutout system and may produce an error (if the
cutout is initially engaged during startup). Therefore, inverting the cutout signal is not
recommended. Furthermore, changing the cutout signal polarity is also not recommended; since some machines
perform a system check of the cutout signal during startup.
The light tower test function turns on all the lights on the light tower to check the lights are
functioning correctly. By default the green and orange lights will be solid and the red light
will flash. The flashing function can be modified by changing the switch on the top of each
light. Twist the top of the top most light in the clockwise direction to access the switch (this is only possible on the old style light towers).
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