eqss Gen-3 LMS Installation Manual
  1. Manuals
  2. Brands
  3. eqss Manuals
  4. Industrial Equipment
  5. Gen-3 LMS
  6. Installation manual

eqss Gen-3 LMS Installation Manual

Telehandler load management system
Hide thumbs Also See for Gen-3 LMS:
Table of Contents

Advertisement

Quick Links

Download this manual
EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for MLT960
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: 1805241756

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Gen-3 LMS and is the answer not in the manual?

Questions and answers

Related Manuals for eqss Gen-3 LMS

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 MLT960 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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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.........................11 Cable Reeler Installation.....................13 Cable Reeler Mounting Position................15 Pressure Sensor Installation..................16 Main Lift Cylinder....................16 Compensation Pressure Sensors................19 Reverse Camera......................20 Cutout Cable Harness....................22 Forward Camera......................25 Signal Light Installation....................27 Can Pressure Input Module (CPIM)................29 External Cable Completion..................30 Display Installation......................32 User Control........................33...
  • Page 5 Appendix B: Reattach Ferrites...................51 Indexes and Tables.....................52 VER: 1805241756 5 of 53...

  • 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: 1805241756 9 of 53...

  • Page 10: Illustration 2: Machine Chassis

    Illustration 2: Machine Chassis VER: 1805241756 10 of 53...

  • Page 11: Covers

    Covers Remove the following covers before starting the installation Step Description Diagram Remove the rear covers behind the boom. Remove the first panel under the chassis at the rear of the machine Remove the first panel under the chassis at the front of the machine Remove the panels under the boom VER: 1805241756 11 of 53...

  • Page 12: Table 3: Cover Removal

    Step Description Diagram Remove the side panel next to the cabin under the boom. Remove the cover behind the cabin Inside the cabin remove the dashboard display. Remove the panel under the joystick Table 3: Cover removal VER: 1805241756 12 of 53...

  • Page 13: 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 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, and secure using the supplied p-clips to the existing threaded holes running down the boom. 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: 1805241756 15 of 53...

  • 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 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.
  • Page 17 Step Description Diagram Disconnect the hose coming from the spool assembly for the main rod pressure line. Note: Some of the existing hoses connected to the spool assembly will need to be removed to access the main rod pressure line. Connect the supplied hydraulic tee connection and pressure sensor into Note: The pressure sensor supplied...

  • Page 18: Table 5: Main Lift Cylinder - Boom Suspension Option

    Step Description Diagram Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors. Cable tie the main head pressure sensor cable 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 19: Compensation Pressure Sensors

    Compensation Pressure Sensors Step Description Diagram Disconnect the flexible hydraulic hoses connected to the compensation cylinder under the rear of the machine. Connect the supplied hydraulic tee connection and pressure sensor into the compensation head pressure line. View from under the machine at the rear Connect the supplied hydraulic tee connection and pressure sensor into...

  • Page 20: 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 21 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...

  • Page 22: 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. Note: The location of the ECU modules may be different from the photo. Pull the connector on the left of the connector to disconnect from the ECU.
  • Page 23 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 24: Table 8: Cutout Cable Harness Installation

    Table 8: Cutout Cable Harness Installation For further details on running the cutout cable harness refer to the Installation Index on page 7 VER: 1805241756 24 of 53...

  • Page 25: 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 26 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: 1805241756 26 of 53...

  • Page 27: 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 28: Table 10: 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 30. Table 10: Signal Light Installation VER: 1805241756 28 of 53...

  • Page 29: 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 30: 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 31: Table 12: External Cable Completion

    Step Description Diagram Run the CCIM, signal light, 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 32: 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 13: Display Installation Adjust the display bracket for optimal viewing angle once the...

  • Page 33: User Control

    User 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. Note: Ensure the cover can be reinstalled without hitting the user control.

  • Page 34: 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 35: 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 cover below the joystick. Connect the 12 pin tee connector into X67. Run the cable through under the dashboard with the other cables.

  • Page 36: 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 37: 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 38 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.

  • Page 39: Table 18: 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 18: 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 40: 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 41 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 42: 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 43 Complete the system checklist once installation has been completed. VER: 1805241756 43 of 53...

  • Page 44: 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 45 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 46: 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 47: 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 48: 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 49: 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: 1805241756 49 of 53...

  • Page 50: 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 51: Table 22: Reattach Ferrites Procedure

    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 52 Indexes and Tables Illustration Index Illustration 1: Machine Boom..................9 Illustration 2: Machine Chassis...................10 Illustration 3: Cable Reeler Mounting Position............15 Illustration 4: Damaged Display Connector..............49 Illustration 5: Do Not Use Tools To Tighten Connector...........49 Illustration 6: Do Not Over Tighten Nuts..............50 Index of Tables Table 1: Component Installation Index................7 Table 2: Cable Installation Index..................8...
  • Page 53 __________________________________________________________________________________ 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: 1805241756 53 of 53...

This manual is also suitable for:

Mlt960

Table of Contents