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

Telehandler load management system for privilege mt1840 standard manual tool recognition
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EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for Privilege MT1840 Standard
Manual Tool Recognition
PLEASE NOTE:
***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: 1607261314

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  • Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for Privilege MT1840 Standard Manual Tool Recognition PLEASE NOTE: ***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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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..................6 Installation Index......................7 Covers.........................12 Cable Reeler Installation.....................14 Cable Reeler Mounting Position................17 Pressure Sensor Installation..................18 Pressure Manifold....................18 Compensation Pressure Sensors................20 Reverse Camera......................21 Cutout Cable Harness....................23 Forward Camera......................26 Stabiliser Cable Harness.....................28 Signal Light Installation....................29 Machine Input Harness....................31 Can Pressure Input Module (CPIM)................32 External Cable Completion..................33 Display Installation......................35...
  • Page 5 Appendix A: Attaching Display Connectors...............51 Indexes and Tables.....................55 VER: 1607261314 5 of 56...

  • 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 Signal Light Cable Aqua Rear Camera Cable Dark Purple CCIM Cable Yellow/Green Cutout/Platform Cable Harness Brown Machine Input Harness Dark Yellow Stabiliser Harness...

  • Page 9: Illustration 1: Machine Boom

    Illustration 1: Machine Boom VER: 1607261314 9 of 56...

  • Page 10: Illustration 2: Machine Chassis

    Illustration 2: Machine Chassis VER: 1607261314 10 of 56...

  • Page 11: Illustration 3: Front Of Machine

    Illustration 3: Front of Machine VER: 1607261314 11 of 56...

  • 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: 1607261314 12 of 56...

  • Page 13: Table 3: Cover Removal

    Step Description Diagram Remove the cover behind the cabin Inside the cabin remove the dashboard display. Table 3: Cover removal VER: 1607261314 13 of 56...

  • Page 14: 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 15: Table 4: Cable Reeler Installation

    Step Description Diagram Drill and tap the M6 holes for the stow switch trigger bracket. Mount the stow switch trigger bracket using the supplied M6 x 12 mm bolts and washers. Adjust the length of the trigger plate to ensure the stow switch is pressed when the boom is retracted.
  • Page 16 For further details on running the boom cable refer to the Installation Index on page 7 VER: 1607261314 16 of 56...

  • Page 17: Cable Reeler Mounting Position

    Cable Reeler Mounting Position Illustration 4: Cable Reeler Mounting Position VER: 1607261314 17 of 56...

  • Page 18: 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 19: Table 5: 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 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 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 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 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...

  • 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.

  • Page 25: Table 8: Rear 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 33. Note: The green wire on the cutout cable harness is only used with Access (A) machines. Cut off and tape up the green wire.

  • 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: 1607261314 27 of 56...

  • Page 28: 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 29: 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 Mount the signal light on the top of the roof past the roof window towards the cabin door.

  • Page 30: Table 11: Signal Light Installation

    Step Description Diagram Run the cable along the pipes under the cover towards the chassis. Cable tie with the other cables during External Cable Completion on page 33. Table 11: Signal Light Installation VER: 1607261314 30 of 56...

  • Page 31: 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 into X67. Run the other end of the cable with the 4 pin connector towards the cabin and cable tie with the other...

  • Page 32: 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 33: External Cable Completion

    External Cable Completion All external cabling is completed in this step. Step Description Diagram Locate the reverse camera cable and run both cables up to the CPIM. View from under the boom towards the rear of the machine At the front of the machine cable tie the stabiliser and front camera cables together up to the CPIM.

  • Page 34: Table 14: 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, signal light, cutout cable harness, stabiliser cable harness, machine input harness and camera cables up through the hole into the cabin under the dashboard.

  • Page 35: 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 36: 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 37: 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 38: 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 39 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 and the 5 pin cable from the user control through the gap between the window and the dashboard.

  • Page 40: Table 18: Cabin Loom Installation

    Step Description Diagram Run the cables through snake tube. Place cable tie points on the side of the window. Cable tie the snake tube to the cable tie points. Connect into the 8 pin and 5 pin connectors into the display Table 18: Cabin Loom Installation If the M12 screw lock connectors on the display are over tightened it will twist the connector pins attaching the...

  • 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.

  • Page 43: Table 19: 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 Complete the system checklist once installation has been completed. VER: 1607261314 44 of 56...

  • Page 45: 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 46 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 47: Table 20: 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 48: Schematics

    Schematics VER: 1607261314 48 of 56...
  • Page 49 VER: 1607261314 49 of 56...
  • Page 50 VER: 1607261314 50 of 56...
  • Page 51 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 52: Table 21: 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 53: Illustration 5: Damaged Display Connector

    Illustration 5: Damaged Display Connector Do not use any tools to tighten the connector. Illustration 6: Do Not Use Tools To Tighten Connector VER: 1607261314 53 of 56...

  • Page 54: Illustration 7: 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 7: Do Not Over Tighten Nuts Damage to the display connectors is not covered under warranty.
  • Page 55 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............17 Illustration 5: Damaged Display Connector..............53 Illustration 6: Do Not Use Tools To Tighten Connector...........53 Illustration 7: Do Not Over Tighten Nuts..............54 Index of Tables Table 1: Component Installation Index................7 Table 2: Cable Installation Index..................8...
  • Page 56 __________________________________________________________________________________ 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: 1607261314 56 of 56...

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