eqss Gen-3 LMS Installation Manual
Telehandler load management system for mlt840 manual tool recognition
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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 MLT840 Manual Tool Recognition Failure To Follow Installation Manual Will Void Warranty VER: 20150513...
- 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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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.
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Page 4: Table Of Contents
Table of Contents Tools Required for Installation..................6 Installation Index......................7 Covers.........................11 Cable Reeler Installation.....................13 Cable Reeler Mounting Position................15 Pressure Sensor Installation..................16 Main Lift Cylinder – Standard Configuration............16 Main Lift Cylinder – Boom Suspension Option............18 Compensation Pressure Sensors................20 Reverse Camera......................21 Cutout Cable Harness....................23 Forward Camera......................26 Light Tower Installation....................28 Light Tower Bracket Mounting Position..............29... - Page 5 Indexes and Tables.....................46 VER: 20150513 5 of 47...
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Page 6: 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 7: 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 8: Table 2: Cable Installation Index
Colour Cable Description Yellow Boom Cable Dark Green Main Cylinder Pressure Sensor Cables Dark Blue Compensation Cylinder Pressure Sensors Cables Light Blue Forward Camera Cable Violet Light Tower Cable Aqua Rear Camera Cable Dark Yellow CCIM Cable Light Green Cutout Harness Display Cable Orange User Input Control Cable... -
Page 9: Illustration 1: Machine Boom
Illustration 1: Machine Boom VER: 20150513 9 of 47... -
Page 10: Illustration 2: Machine Chassis
Illustration 2: Machine Chassis VER: 20150513 10 of 47... -
Page 11: Covers
Covers Remove the following covers before starting the installation Step Description Diagram Remove the rear cover behind the boom. Remove the side panel next to the cabin under the boom. Remove the cover behind the cabin VER: 20150513 11 of 47... -
Page 12: Table 3: Cover Removal
Step Description Diagram Inside the cabin remove the dashboard display. Table 3: Cover removal VER: 20150513 12 of 47... -
Page 13: 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 the holes for the cable reeler according to the mounting diagram on page 15. Mount using the supplied bolts and washers. -
Page 14: Table 4: Cable Reeler Installation
Step Description Diagram Connect the supplied M12 10 metre cable (CB001027) into the cable reeler connection. Run the cable down the top of the boom, place cable tie points every 500 mm down the boom and secure the cable to the cable tie points. Cable tie to the flexible hydraulic hoses down to the chassis. -
Page 15: Cable Reeler Mounting Position
Cable Reeler Mounting Position Illustration 3: Cable Reeler Mounting Position VER: 20150513 15 of 47... -
Page 16: Pressure Sensor Installation
Pressure Sensor Installation The hydraulic pressure sensors are used to measure the lifting load of the telehandler. Main Lift Cylinder – Standard Configuration Failure to tighten the bolts to the correct torque on the pressure manifold may result in a pressure failure on the counterbalance valve causing an uncontrolled fall of the boom. -
Page 17: Table 5: Main Lift Cylinder - Standard Configuration
Step Description Diagram Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors. Cable tie 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 18: Main Lift Cylinder - Boom Suspension Option
Main Lift Cylinder – Boom Suspension Option Step Description Diagram Raise the boom and 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. Remove the pressure sensor connected to the PX port of the main head pressure line on the... -
Page 19: Table 6: Main Lift Cylinder - Boom Suspension Option
Step Description Diagram Disconnect the hose coming from the main rod pressure line into the left side of the counterbalance manifold mounted on the chassis. Connect the supplied hydraulic tee connection and pressure sensor into the main rod pressure line. Ensure the pressure sensor is aligned as shown in the picture, so View from under the compensation... -
Page 20: Compensation Pressure Sensors
Compensation Pressure Sensors Step Description Diagram Install the pressure sensor with the U shaped hydraulic connection into the rod of the compensation cylinder View from behind the cabin towards the center of the machine Install the head compensation pressure sensor into the compensation cylinder Start the machine, pressurise the boom and check for leaks. -
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 The camera's viewing angle may need to be adjusted once the system is installed and the display is operational. Once the cable has been secured with a cable tie disconnect the cable to remove the rear cover until the installation is finalised For further details on running the camera cable refer to the Installation Index on page 7...
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Page 23: Cutout Cable Harness
Cutout Cable Harness Isolate the main battery before connecting into the machine wiring Step Description Diagram Remove connector X148 from the ECU MP1. Pull the connector on the left of the connector to disconnect from the ECU. Slide the protective cover off the end of the connector to access the wires. - Page 24 Step Description Diagram Remove the blanking pin from the connector in slot 4 and insert the blue wire from the cutout harness. Note: The pin numbers are written on the front of the connector Replace the pin support bracket and the protective cover.
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Page 25: Table 9: Cutout Cable Harness Installation
Step Description Diagram Run the snake tube and cables towards the cabin and cable tie with the other cables during External Cable Completion on page 32. Table 9: Cutout Cable Harness Installation For further details on running the cutout cable harness refer to the Installation Index on page 7 The green wire on the wire harness is not needed to complete the installation for this machine configuration. -
Page 26: 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 27 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 7 VER: 20150513 27 of 47...
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Page 28: 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 the holes required to mount the light tower bracket on the chassis according to the mounting diagram on page 29. -
Page 29: Light Tower Bracket Mounting Position
Light Tower Bracket Mounting Position Illustration 4: Light Tower Bracket Mounting Position VER: 20150513 29 of 47... -
Page 30: Machine Input Harness
Machine Input Harness Isolate the main battery before connecting into the machine wiring Step Description Diagram Locate the 12 pin connector under the boom next to the cabin, that connect into the joystick. Connect the 12 pin tee connector from the machine input harness into X67. -
Page 31: 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 32: External Cable Completion
External Cable Completion All external cabling is completed in this step. Step Description Diagram Coil up and cable tie the additional cabling for the boom and pressure sensor cables and store underneath the CPIM. Connect the supplied M12 4 metre cable (CB001026) into the free connection out of the right side of the CPIM for the CCIM cable. -
Page 33: Table 14: External Cable Completion
Step Description Diagram Run the CCIM, light tower, cutout harness, machine input harness and camera cables up through the hole into the cabin under the dashboard. Note: Pull the entire length of cable through into the cabin, excess cable will be stored under the dashboard cover in the cabin. -
Page 34: Display Installation
Display Installation The display shows the current safety status of the telehandler. Step Description Diagram Attach the display bracket to the level indicator in the top right corner using the supplied M6 x 35 mm bolts and nuts. Attach the display to the bracket and tighten the grub screw Table 15: Display Installation Adjust the display bracket for optimal viewing angle once the... -
Page 35: User Input Control
User Input Control The user input control consists of a 5 button switch mounted in the dashboard. Step Description Diagram Drill a 34 mm hole into the cover in front of the joystick and install the user control dial. Note: Be careful while drilling not to damage the hydraulic controls positioned under the cover. -
Page 36: Can Cabin Interface Module (Ccim)
Can Cabin Interface Module (CCIM) The CCIM connects the system into the machine electronics. Step Description Diagram Position the backup battery (to the right of the CCIM) underneath the dashboard using double sided velcro tape. Position the CCIM to the left of the backup battery using double sided velcro tape. -
Page 37: Override Wiring
Override Wiring The following connections are located behind the dashboard display in the cabin. Isolate the main battery before connecting into the machine wiring Step Description Diagram Locate the dashboard display connector (X13). Cut wire 124 into the connector. Join the yellow wire from the machine input harness to the side of wire 124 leading towards the connector. -
Page 38: 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. Isolate the main battery before connecting into the machine wiring Step Description... - Page 39 Step Description Diagram Connect the camera power and signal cables to the cabin loom. Note: The white connector is not used. Attach the ring lug from the cutout cable to the ground lug inside the dashboard. Run the 8 pin cable from the CCIM and the 5 pin cable from the user control through the gap between the window and the dashboard.
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Page 40: Table 19: Cabin Loom Installation
Step Description Diagram Run the cable through snake tube. Place cable tie points on the side of the window. Cable tie the snake tube to the cable tie points. Table 19: Cabin Loom Installation VER: 20150513 40 of 47... -
Page 41: Finalisation
Finalisation This section will complete the final power connections to power the system and finish any additional items. Step Description Diagram Connect the radio power harness into the radio power connector. Ensure there is a 2A fuse installed in F10 and a 7.5A fuse installed in F26 for radio power. - Page 42 Step Description Diagram Attach the backup battery and CCIM to the velcro strips installed earlier. Coil up the extra cables and store underneath the dashboard cover. Reconnect the main battery from the isolation switch. Turn the machine onto first stage /accessories and ensure the system is activated.
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Page 43: Table 20: 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 44: 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 45: Table 21: 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 21: Sensor Calibration VER: 20150513 45 of 47... - Page 46 Indexes and Tables Illustration Index Illustration 1: Machine Boom..................9 Illustration 2: Machine Chassis...................10 Illustration 3: Cable Reeler Mounting Position............15 Illustration 4: Light Tower Bracket Mounting Position..........29 Index of Tables Table 1: Component Installation Index................7 Table 2: Cable Installation Index..................8 Table 3: Cover removal....................12 Table 4: Cable Reeler Installation................14 Table 5: Main Lift Cylinder –...
- Page 47 __________________________________________________________________________________ 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: 20150513 47 of 47...
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