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

Telehandler load management system for t4018
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EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for T40180
***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***
VER: 1906121521

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  • Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for T40180 ***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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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 Installation Index......................6 Covers.........................10 Cable Reeler Installation.....................12 Cable Reeler Mounting Position................16 Pressure Sensor Installation..................17 Pressure Manifold....................17 Compensation Pressure Sensors................19 Reverse Camera......................21 Can Pressure Input Module (CPIM)................23 Signal Light Installation....................24 Stabiliser Connections....................27 Forward Camera......................28 External Cable Completion..................30 Display Installation......................33 User Input Control.......................35 Can Cabin Interface Module (CCIM)................36...

  • Page 5: Tools Required For Installation

    Indexes and Tables.....................58 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 ◦ 6.8 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 Light Purple Boom Cable Dark Green Main Cylinder Pressure Sensor Cables Dark Blue Compensation Cylinder Pressure Sensors Cables Cutout Harness Orange Lock Pin Release Harness Light Green Forward Camera Cable Brown Signal Light Cable Light Blue Rear Camera Cable Dark Purple CCIM Cable Dark Brown...

  • Page 8: Illustration 1: Machine Boom

    Illustration 1: Machine Boom VER: 1906121521 8 of 59...

  • Page 9: Illustration 2: Machine Chassis

    Illustration 2: Machine Chassis VER: 1906121521 9 of 59...

  • Page 10: Covers

    Covers Remove the following covers before starting the installation Step Description Diagram Remove the rear covers. Remove the cover behind the cabin Remove the cover in front of the cabin behind the front left wheel. VER: 1906121521 10 of 59...

  • Page 11: Table 3: Cover Removal

    Step Description Diagram Undo the bolts attaching the dashboard. Table 3: Cover removal VER: 1906121521 11 of 59...

  • Page 12: 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 13 Step Description Diagram Weld the stow switch and anchor mounting bracket to the first extendable section, in position that will trigger the stow switch when the boom is retracted. Note: Ensure the mounting bracket is welded on the first extendable section not on the last section.

  • Page 14: Table 4: Cable Reeler Installation

    Step Description Diagram Run the cable up to the top of the boom. Place cable ties points down the top of the boom as shown. Cable tie the boom cable to the cable tie points down the boom. Cable tie to the flexible hydraulic hoses from the end of the tube down to the chassis.
  • Page 15 For further details on running the boom cable refer to the Installation Index on page 6 VER: 1906121521 15 of 59...

  • Page 16: Cable Reeler Mounting Position

    Cable Reeler Mounting Position Illustration 3: Cable Reeler Mounting Position VER: 1906121521 16 of 59...

  • Page 17: Pressure Sensor Installation

    Pressure Sensor Installation The hydraulic pressure sensors are used to measure the lifting load of the telehandler. Pressure Manifold 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 18 For further details on running the pressure sensor cables refer to the Installation Index on page 6 VER: 1906121521 18 of 59...

  • Page 19: Compensation Pressure Sensors

    Compensation Pressure Sensors Step Description Diagram Undo the hydraulic connection for the head compensation into the manifold block at the rear of the machine. Install the supplied tee piece and pressure sensor in line with the hydraulic connection. View from behind the machine Undo the hydraulic connection for the rod compensation into the compensation cylinder.
  • Page 20 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: 1906121521 20 of 59...

  • Page 21: 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 22: Table 7: Reverse Camera Installation

    Step Description Diagram Place the “No High Pressure Washing” sticker above the installed rear camera on the back panel. Table 7: Reverse Camera Installation 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: 1906121521...

  • Page 23: Can Pressure Input Module (Cpim)

    Can Pressure Input Module (CPIM) The CPIM is responsible for processing the information send from the pressure sensors. Accidentally swapping the pressure sensor connections will not damage the system. Do not plug the pressure sensor cable into the far right side boom cable.

  • Page 24: 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 Windshield Guard Mount the signal light to the top windscreen guard using the supplied...
  • Page 25 Step Description Diagram Run the signal light cable down towards the cabin grommet and secure in place using the cable tie adhesive strips. Inside the cabin remove the cover on the roof to access the cabin grommet. Cut 200mm from the connector end of the light tower cable in order to feed the cable through the rear roof grommet.

  • Page 26: Table 9: Signal Light Installation

    Step Description Diagram Run the signal light cable along the roof to the other side of the cabin. Run the cable from the roof and secure in place using the cable tie adhesive strips. Run the cable under the plastics covers to the dashboard, to connect into the CCIM.

  • Page 27: Stabiliser Connections

    Stabiliser Connections The stabiliser switches indicate to the system when the stabilisers are lowered providing extra stability. Step Description Diagram Run the Pressure Sensor Stabiliser Harness (AS001876) from the CCIM harness inside the cabin, through the grommet to the front of the machine, using the path shown in the image to the right.

  • Page 28: 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 29 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: 1906121521 29 of 59...

  • Page 30: External Cable Completion

    External Cable Completion All external cabling is completed in this step. Step Description Diagram Locate the cable entrance hole from the inside of the cabin to the outside of the chassis, located inside the dashboard to outside the front of the cabin.
  • Page 31 Step Description Diagram Run the cutout and lock pin release harnesses along the same path under the chassis covers as the existing electrical harnesses towards the spool assembly at the rear of the machine. Run the CCIM and rear camera cables along the same path as the existing electrical harnesses towards and through the hole into...

  • Page 32: Table 12: External Cable Completion

    Step Description Diagram Coil up the additional cabling for the pressure sensor, CCIM, signal light and boom cables and store under the cabin behind the CPIM. View from behind the cabin At the front of the machine cable tie the stabiliser switches and forward camera harnesses together and run towards the cabin.

  • Page 33: Display Installation

    Display Installation The display shows the current safety status of the telehandler. Step Description Diagram Remove the rear mirror from the right colomn. Using the supplied M3 screws, Plastic Sleeve, and bolts, mount the Display Bracket to the same mounting location of the removed rear-view mirror.
  • Page 34 Adjust the display bracket for optimal viewing angle once the display is powered If the M12 screw lock connectors on the display are over tightened it will twist the connector pins attaching the connector to the PCB. See Appendix A: Attaching Display Connectors on page 53 for the correct method of attaching to the display connectors.

  • Page 35: User Input Control

    User Input Control The user input control consists of a single dial switch mounted in the dashboard. Step Description Diagram Drill a 34 mm hole into the location shown shown below the park brake switch. Install the user input control dial in the dashboard, aligned so the Enter cap is facing up.

  • Page 36: Can Cabin Interface Module (Ccim)

    Can Cabin Interface Module (CCIM) The CCIM connects the system into the machine electronics. Step Description Diagram Install the CCIM and backup battery onto the flat plate under the dashboard switches. Secure in place using velcro tape. Remove the battery and CCIM from the velcro to allow the connections to be completed.

  • Page 37: 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 After completing the machine connections the boom can not be moved until the installation is complete Step Description Diagram...
  • Page 38 Step Description Diagram Locate the override switch terminal C218 in the removable dashboard panel. Remove the fork terminal connected to blue wire #3310 from the override switch terminal and replace with the violet wire from the machine input harness. Cut off the fork terminal on the blue wire #3310 and join to the yellow wire from the machine input harness.

  • Page 39: Table 16: Machine Connections

    Step Description Diagram Locate the following connectors underneath the joystick: C259 C257 Connect the Stabiliser Switch Harness (AS001877) to the following wires using the supplied crimp connectors: AS001877 Wire ID to Harness Connector Splice BLUE C259 3610 (LEFT STAB) GREEN C257 3550 (RIGHT...

  • Page 40: Cabin Loom

    Cabin Loom The cabin loom connects the CCIM to the machine connections and the other modules of the system. Do not disconnect the camera power connection while the system is operating as this can damage the fuse. Step Description Diagram Connect the CCIM and signal light cables to the M12 connectors on the CCIM.
  • Page 41 Step Description Diagram Connect the 2 pin connector from the stabiliser harness into the IO harness. Attach the ring lug from the stabiliser harness to the ground point in the cabin. Connect the 4 pin connector from the machine input harness into the IO harness.

  • Page 42: Table 17: Cabin Loom Installation

    Step Description Diagram Connect the spade lug on the black wire to the negative (black) battery terminal on the backup battery. Connect the spade lug on the blue wire to the positive (red) battery terminal on the backup battery. Table 17: Cabin Loom Installation 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 43: Finalisation

    Finalisation This section will complete the final power connections to power the system and finish any additional items. Step Description Diagram Connect the 3 pin connector from the radio power harness into the power/camera harness. Coil up and store the wire harnesses under the dashboard.
  • Page 44 Step Description Diagram Reconnect the tee connectors back into the safety valve and the cable through boom connection. Note: Make sure the connections for the cable through boom and placed behind the hydraulic pipes so as not to get crushed against the rear cover once installed.

  • Page 45: Table 18: Finalisation

    Step Description Diagram Operate the boom movement controls to test if a false N07 fault occurs. If a N07 fault does occur, adjust the arm on the stow switch forwards towards the stow switch trigger. Note: The actual switch arm orientation may differ from the picture.

  • Page 46: 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 47 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 48: Table 19: 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 49: Schematics

    Schematics VER: 1906121521 49 of 59...
  • Page 50 VER: 1906121521 50 of 59...
  • Page 51 VER: 1906121521 51 of 59...
  • Page 52 VER: 1906121521 52 of 59...

  • Page 53: 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 54: Table 20: 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 55: Illustration 4: Damaged Display Connector

    Illustration 4: Damaged Display Connector Do not use any tools to tighten the connector. Illustration 5: Do Not Use Tools To Tighten Connector VER: 1906121521 55 of 59...

  • Page 56: Illustration 6: 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 6: Do Not Over Tighten Nuts Damage to the display connectors is not covered under warranty.

  • Page 57: 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 58 Indexes and Tables Illustration Index Illustration 1: Machine Boom..................8 Illustration 2: Machine Chassis..................9 Illustration 3: Cable Reeler Mounting Position............16 Illustration 4: Damaged Display Connector..............55 Illustration 5: Do Not Use Tools To Tighten Connector...........55 Illustration 6: Do Not Over Tighten Nuts..............56 Index of Tables Table 1: Component Installation Index................6 Table 2: Cable Installation Index..................7...
  • Page 59 __________________________________________________________________________________ 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: 1906121521 59 of 59...

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