eqss MLT741 Installation Manual
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eqss MLT741 Installation Manual

Gen-3 lms telehandler load management system
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EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for MLT741 / MT732
Manual Tool Recognition
***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: 1906271122

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  • Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for MLT741 / MT732 Manual Tool Recognition ***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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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 Pressure Manifold....................16 Compensation Pressure Sensors................18 Reverse Camera......................19 SPU Cable Harness.....................21 Machine Input Harness....................23 Forward Camera......................24 Signal Light Installation....................26 Can Pressure Input Module (CPIM)................28 External Cable Completion..................29 Display Installation......................31 User Input Control.......................32...
  • Page 5 VER: 1906271122 5 of 52...

  • 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 Light Green Cutout Harness Display Cable Orange User Input Control Cable...

  • Page 9: Illustration 1: Machine Boom

    Illustration 1: Machine Boom VER: 1906271122 9 of 52...

  • Page 10: Illustration 2: Machine Chassis

    Illustration 2: Machine Chassis Note: The old light tower is shown VER: 1906271122 10 of 52...

  • Page 11: Covers

    Covers Remove the following covers before starting the installation Step Description Diagram Remove the top cover behind the boom. Remove the side panel next to the cabin under the boom. Inside the cabin remove the dashboard. VER: 1906271122 11 of 52...

  • Page 12: Table 3: Cover Removal

    Step Description Diagram Remove the cover over the fluid containers Remove the cover over the SPU behind the seat Table 3: Cover removal VER: 1906271122 12 of 52...

  • 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 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 15: Cable Reeler Mounting Position

    Cable Reeler Mounting Position Illustration 3: Cable Reeler Mounting Position VER: 1906271122 15 of 52...

  • Page 16: 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 17: 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 18: Compensation Pressure Sensors

    Compensation Pressure Sensors Step Description Diagram Install the pressure sensors with the tee connections into the head and rod of the compensation cylinder. Start the machine, pressurise the boom and check for leaks. Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors.

  • Page 19: 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 20 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 21: Spu Cable Harness

    SPU and insert the cutout terminal into MT732 - A22 (where A is the • smaller connector). MLT741 – B21 (where B is the • larger connector) Cable tie to the SPU snake tube. Run the snake tube and cables...
  • Page 22 For further details on running the spu cable harness refer to the Installation Index on page 7 VER: 1906271122 22 of 52...

  • Page 23: Machine Input Harness

    Machine Input Harness Isolate the main battery before connecting into the machine wiring Step Description Diagram Locate the connectors under the boom next to the cabin, that connect into the joystick. Connect the 12 pin tee connector into X67. Run the cable towards the cabin and cable tie with the other cables during External Cable Completion on page 29.

  • Page 24: 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 25 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: 1906271122 25 of 52...

  • Page 26: 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 27: 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 29. Table 11: Signal Light Installation VER: 1906271122 27 of 52...

  • Page 28: 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 29: 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 pressure sensor and boom cables and store inside the chassis. 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 30: Table 13: External Cable Completion

    Step Description Diagram Cable tie the CCIM, signal light, rear camera, cutout and machine input harnesses together along the side to the front of the cabin. Run the CCIM, cutout harness, machine input harness, signal light and camera cables up through the hole into the cabin under the dashboard.

  • Page 31: 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 14: Display Installation Adjust the display bracket for optimal viewing angle once the...

  • Page 32: 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 33: 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 underneath the dashboard as shown and secure using double sided velcro tape. Position the CCIM next to the brake fluid container as shown and secure using double sided velcro tape.

  • Page 34: 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 35 Step Description Diagram Connect the camera power and signal cables to the cabin loom. Note: The white connector is not used. Connect the 4 pin female connector from the machine input harness, the 6 pin female connector from the cutout cable harness and the 2 pin and 12 pin connectors from the stabiliser harness to the cabin loom connectors.

  • Page 36: Table 17: Cabin Loom Installation

    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. See Appendix A: Attaching Display Connectors on page 46 for the correct method of attaching to the display connectors.

  • Page 37: Finalisation

    Finalisation This section will complete the final power connections to power the system and finish any additional items. Step Description Diagram Cut wire 478 into terminal 1 of the switch. Join the yellow wire from the machine input harness to side of wire 478 leading towards the switch.
  • Page 38 Step Description Diagram Attach the 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 39: Table 18: Finalisation

    Step Description Diagram Perform a final check on all the cabling and sensors. Replace all the covers Table 18: Finalisation Make sure to update the machine ECU software for Australian configuration using the Manitou pad. Complete the system checklist once installation has been completed.

  • Page 40: 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 41 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 42: 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 43: Schematics

    Schematics VER: 1906271122 43 of 52...
  • Page 44 VER: 1906271122 44 of 52...
  • Page 45 VER: 1906271122 45 of 52...

  • Page 46: 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 47: 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 48: 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: 1906271122 48 of 52...

  • Page 49: 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 50: 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 51: Indexes And Tables

    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..............48 Illustration 5: Do Not Use Tools To Tighten Connector...........48 Illustration 6: Do Not Over Tighten Nuts..............49 Index of Tables Table 1: Component Installation Index................7 Table 2: Cable Installation Index..................8...
  • Page 52 __________________________________________________________________________________ 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: 1906271122 52 of 52...

This manual is also suitable for:

Mt732

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