eqss Gen3 LMS Installation Manual
Telehandler load management system for privilege mt1840 a / ep manual tool recognition
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- Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for Privilege MT1840 A / EP 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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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.........................12 Cable Reeler Installation.....................14 Cable Reeler Mounting Position................16 ID Reader Installation....................17 ID Reader Mounting Position..................20 Pressure Sensor Installation..................21 Pressure Manifold....................21 Compensation Pressure Sensors................23 Reverse Camera......................24 Cutout Cable Harness....................26 Forward Camera......................29 Stabiliser Cable Harness.....................31 Light Tower Installation....................32 Light Tower Bracket Mounting Position..............33 Machine Input Harness....................34... - Page 5 Finalisation........................45 Sensor Calibration.......................48 Schematics........................50 Indexes and Tables.....................53 VER: 20150513 5 of 54...
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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 Purple CCIM Cable Yellow/Green Cutout Cable Harness Brown Joystick Cable Harness Dark Yellow Stabiliser Harness... -
Page 9: Illustration 1: Machine Boom
Illustration 1: Machine Boom VER: 20150513 9 of 54... -
Page 10: Illustration 2: Machine Chassis
Illustration 2: Machine Chassis VER: 20150513 10 of 54... -
Page 11: Illustration 3: Front Of Machine
Illustration 3: Front of Machine VER: 20150513 11 of 54... -
Page 12: Covers
Covers Remove the following covers before starting the installation Step Description Diagram Remove the top rear cover behind the boom. Remove the side panel next to the cabin under the boom. Remove the covers under the boom. Remove the covers over the stabiliser connections VER: 20150513 12 of 54... -
Page 13: Table 3: Cover Removal
Step Description Diagram Remove the cover behind the cabin Inside the cabin remove the dashboard display. Remove the fuse box cover. Table 3: Cover removal VER: 20150513 13 of 54... -
Page 14: 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 support brackets according to the mounting diagram on page 16. Mount using the supplied countersunk M8 x 16 mm bolts. -
Page 15: Table 4: Cable Reeler Installation
Step Description Diagram Connect the supplied M12 10 metre cable (CB001027) into the cable reeler connection. 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. -
Page 16: Cable Reeler Mounting Position
Cable Reeler Mounting Position Illustration 4: Cable Reeler Mounting Position VER: 20150513 16 of 54... -
Page 17: Id Reader Installation
ID Reader Installation The ID reader is mounted on the front of the attachment head and is used to determine the attachment in use. Step Description Diagram Drill the holes for the ID reader according to the mounting description on page 20. Remove the M4 bolts attaching the ID reader to the mounting bracket, to allow access to the bracket... - Page 18 Step Description Diagram Drill and tap two M6 holes to attach the supplied metal hose clamp to the attachment head. Ensure the clamp is pointing in the direction shown. Wrap the cable hose around the attachment head pivot. Secure the cable hose to the hose clamp.
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Page 19: Table 5: Id Reeler Installation
Step Description Diagram Cable tie the cable down the cable anchor and along the hydraulic lines leading under the front cover. Remove the front cover and attach the 3 pin connector from the cable reeler to the ID reader connector. Replace the cover. -
Page 20: Id Reader Mounting Position
ID Reader Mounting Position Illustration 5: ID Reader Mounting Position VER: 20150513 20 of 54... -
Page 21: Pressure Sensor Installation
Pressure Sensor Installation The hydraulic pressure sensors are used to measure the lifting load of the telehandler. Pressure Manifold 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 22: Table 6: Pressure Manifold Installation
Step Description Diagram Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors. Add both cables to 3 m of snake tube. 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 23: 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 rear of the machine Install the head compensation pressure sensor into the compensation cylinder Start the machine, pressurise the boom and check for leaks. -
Page 24: 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 25 The camera's viewing angle may need to be adjusted once the system is installed and the display is operational. Once the cable has 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 26: 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 27 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 28: 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 36. Table 9: Cutout Cable Harness Installation For further details on running the cutout cable harness refer to the Installation Index on page 7 VER: 20150513 28 of 54... -
Page 29: 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 30 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 30 of 54...
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Page 31: Stabiliser Cable Harness
Stabiliser Cable Harness Isolate the main battery before connecting into the machine wiring Step Description Diagram Locate the stabiliser down pressure switch connections at the front of the machine. Connect the 3 pin tee connector labelled left stabiliser into X97 and the connector labelled right stabiliser into X87 on the stabiliser cable harness. -
Page 32: 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 33. -
Page 33: Light Tower Bracket Mounting Position
Light Tower Bracket Mounting Position Illustration 6: Light Tower Bracket Mounting Position VER: 20150513 33 of 54... -
Page 34: Machine Input Harness
Machine Input Harness Isolate the main battery before connecting into the machine wiring Step Description Diagram Locate the bundle of connectors under the boom next to the cabin, that connect into the joystick. Connect the 12 pin tee connector into X67. Run the other end of the cable with the 4 pin connector towards the cabin and cable tie with the other... -
Page 35: 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 36: External Cable Completion
External Cable Completion All external cabling is completed in this step. Step Description Diagram Locate the reverse camera cable and the boom cable at the rear of the machine and run both cables through the supplied 2.5 m section of snake tube up to the CPIM. -
Page 37: Table 15: External Cable Completion
Step Description Diagram Connect the supplied M12 4 metre cable (CB001026) into the free connection out of the right side of the CPIM for the CCIM cable. Run the CCIM, cutout cable harness, stabiliser cable harness, light tower, joystick cable harness and camera cables up through the hole into the cabin under the dashboard. -
Page 38: 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 16: Display Installation Adjust the display bracket for optimal viewing angle once the... -
Page 39: 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 40: 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 41: Cabin Fuse Box Wiring
Cabin Fuse Box Wiring The following connections are located near the fuse box beside the seat in the cabin. Isolate the main battery before connecting into the machine wiring Step Description Diagram Locate the function selection switch (S52). Insert the green wire from the cutout cable harness into the terminal with the existing green wires of the access mode switch... -
Page 42: Cabin Loom
Cabin Loom The cabin loom connects the CCIM to the machine connections and the other modules of the system. Isolate the main battery before connecting into the machine wiring Do not disconnect the camera power connection while the system is operating as this can damage the fuse. Step Description Diagram... - Page 43 Step Description Diagram Attach the ring lug from the cutout harness to the ground point underneath the dashboard. Connect the camera power and signal cables to the cabin loom. Note: The white connector is not used. Run the 8 pin cable from the CCIM through the gap between the window and the dashboard.
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Page 44: Table 20: 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 20: Cabin Loom Installation VER: 20150513 44 of 54... -
Page 45: 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 46 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 47: Table 21: 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 48: 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 49: Table 22: 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 22: Sensor Calibration VER: 20150513 49 of 54... -
Page 50: Schematics
Schematics VER: 20150513 50 of 54... - Page 51 VER: 20150513 51 of 54...
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Page 53: Indexes And Tables
Indexes and Tables Illustration Index Illustration 1: Machine Boom..................9 Illustration 2: Machine Chassis...................10 Illustration 3: Front of Machine..................11 Illustration 4: Cable Reeler Mounting Position............16 Illustration 5: ID Reader Mounting Position...............20 Illustration 6: Light Tower Bracket Mounting Position..........33 Index of Tables Table 1: Component Installation Index................7 Table 2: Cable Installation Index..................8 Table 3: Cover removal....................13... - Page 54 __________________________________________________________________________________ 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 54 of 54...
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