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

Telehandler load management system
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EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for T40180 – 2022 Model
***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***
DO001547 VER: 2303241610

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  • Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for T40180 – 2022 Model ***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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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..................5 Installation Index......................6 Covers.........................10 Cable Reeler Installation.....................13 Cable Reeler Mounting Position................16 Pressure Sensor Installation..................17 Pressure Manifold....................17 Compensation Pressure Sensors................19 Can Pressure Input Module (CPIM)................21 Signal Light Installation....................23 Forward Camera......................26 External Cable Completion..................28 Display Installation......................32 User Control........................33 Can Cabin Interface Module (CCIM)................34 Machine Connections....................35...

  • Page 5: 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 ◦ 6.8 mm ◦ 8.5 mm ◦...

  • Page 6: 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 7: Table 2: Cable Installation Index

    Colour Cable Description Light Purple Boom Cable Dark Green Main Cylinder Pressure Sensor Cables Dark Blue Compensation Cylinder Pressure Sensors Cables Cutout Harness Orange Lock Pin Release Harness Light Green Forward Camera Cable Brown Signal Light Cable Dark Purple CCIM Cable Table 2: Cable Installation Index DO001547 VER: 2303241610 7 of 58...

  • Page 8: Illustration 1: Machine Boom

    Illustration 1: Machine Boom Note: The photo above doesn’t show the boom lights and boom light cable that the boom cable is attached to. DO001547 VER: 2303241610 8 of 58...

  • Page 9: Illustration 2: Machine Chassis

    Illustration 2: Machine Chassis DO001547 VER: 2303241610 9 of 58...

  • Page 10: Covers

    Covers Remove the following covers before starting the installation Step Description Diagram Remove the rear covers. Remove the cover behind the cabin Remove the cover in front of the cabin behind the front left wheel. DO001547 VER: 2303241610 10 of 58...
  • Page 11 Step Description Diagram Undo the bolts attaching the dashboard. Remove the cover under the dashboard Remove the switch panel on the side of the cabin and the joystick panel DO001547 VER: 2303241610 11 of 58...

  • Page 12: Table 3: Cover Removal

    Step Description Diagram Remove the cover behind the joystick to route the light tower cables Table 3: Cover removal DO001547 VER: 2303241610 12 of 58...

  • 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 Step Description Diagram Weld the stow switch and anchor mounting bracket to the first extendable section, in position that will trigger the stow switch when the boom is retracted. Note: Ensure the mounting bracket is welded on the first extendable section not on the last section.

  • Page 15: Table 4: Cable Reeler Installation

    Step Description Diagram Run the cable below the boom and secure to the boom lights down to the base of the boom. Run the remainder of the cable towards the cabin and cable tie with the rest of the cables during External Cable Completion on page Table 4: Cable Reeler Installation For further details on running the boom cable refer to the...

  • Page 16: Cable Reeler Mounting Position

    Cable Reeler Mounting Position Illustration 3: Cable Reeler Mounting Position DO001547 VER: 2303241610 16 of 58...

  • Page 17: Pressure Sensor Installation

    Pressure Sensor Installation The hydraulic pressure sensors are used to measure the lifting load of the telehandler. Pressure Manifold Step Description Diagram Raise the boom to approximately 40 degrees. Support and secure the boom using an A Frame or similar apparatus. It must support at least 2 tons.
  • Page 18 For further details on running the pressure sensor cables refer to the Installation Index on page 6 DO001547 VER: 2303241610 18 of 58...

  • Page 19: Compensation Pressure Sensors

    Compensation Pressure Sensors Step Description Diagram Undo the hydraulic connection for the head compensation into the manifold block at the rear of the machine. Install the supplied tee piece and pressure sensor in line with the hydraulic connection. View from under the boom towards the rear of the machine Undo the hydraulic connection for the rod compensation into the...
  • Page 20 Angle the tee connections to ensure the hydraulic connections and pressure sensor do not hit the boom when the boom is lowered For further details on running the pressure sensor cables refer to the Installation Index on page 6 DO001547 VER: 2303241610 20 of 58...

  • Page 21: Can Pressure Input Module (Cpim)

    Can Pressure Input Module (CPIM) The CPIM is responsible for processing the information send from the pressure sensors. Accidentally swapping the pressure sensor connections will not damage the system. Do not plug the pressure sensor cable into the far right side boom cable.

  • Page 22: Table 7: Can Pressure Input Module (Cpim) Installation

    Step Description Diagram Run the height limiter cable from out the left side of the CPIM to the hydraulic block at the rear of the machine. Connect the tee connector labelled “Raise” from the height limiter cable to the boom raise (bottom left) connector on the hydraulic block and the tee connector labelled “Extend”...

  • Page 23: 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 to the top of the cabin using the magnetic anchor.
  • Page 24 Step Description Diagram Cut the signal light cable approximately 300 mm from the end of the M12 connector. Feed the cable through one of the existing grommets for the rotating beacon into the cabin. Note: As an alternative to cutting the cable the grommet hole can be enlarged to fit the M12 connector.

  • Page 25: Table 8: Signal Light Installation

    Step Description Diagram Inside the cabin, reconnect the 4 wire cable using the supplied crimp joiners. Secure the joined connections using electrical tape (not shown) Note: The light tower cable will be connected during Finalisation on page 42. Table 8: Signal Light Installation DO001547 VER: 2303241610 25 of 58...

  • 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 6 DO001547 VER: 2303241610 27 of 58...

  • Page 28: External Cable Completion

    External Cable Completion All external cabling is completed in this step. Step Description Diagram Locate the cable entrance hole from the inside of the cabin to the outside of the chassis, located inside the dashboard to outside the front of the cabin.
  • Page 29 Step Description Diagram Run the cutout and lock pin release harnesses along the same path under the chassis covers as the existing electrical harnesses towards the spool assembly at the rear of the machine. Run the CCIM cable along the same path as the existing electrical harnesses and through the hole into the cabin.
  • Page 30 Step Description Diagram Run the two pin connectors on the cutout harness down to the boom lower connector on the hydraulic block and secure in place using cable ties. This will be connected during Finalisation on page 42. Note: The location of the connectors in the picture above may not match the machine, check the label on the connector...

  • Page 31: Table 10: External Cable Completion

    Step Description Diagram Run the CCIM and camera cable up through the hole into the cabin. Note: Pull a short length of cable through into the cabin. Store excess cable under the cabin. Table 10: External Cable Completion DO001547 VER: 2303241610 31 of 58...

  • Page 32: Display Installation

    Display Installation The display shows the current safety status of the telehandler. Step Description Diagram Remove the rear mirror from the right column. Use the existing bolts to mount the display adaptor bracket to the rear mirror mount. Table 11: Display Installation Adjust the display bracket for optimal viewing angle once the display is powered If the M12 screw lock connectors on the display are over...

  • Page 33: User Control

    User Control The user control consists of a single dial switch mounted in the dashboard. Step Description Diagram Drill a 39 mm hole into the switch panel below the dashboard as shown. Install the user control dial in the dashboard, aligned so the Enter cap is facing up.

  • Page 34: Can Cabin Interface Module (Ccim)

    Can Cabin Interface Module (CCIM) The CCIM connects the system into the machine electronics. Step Description Diagram Install the CCIM and backup battery onto the flat plate under the switch board cover beside the joystick in the location shown. Secure in place using velcro tape. Remove the battery and CCIM from the velcro to allow the connections to be completed.

  • Page 35: Machine Connections

    Machine Connections The following procedures connect the safety systems to the existing electronics in the machine. Isolate the main battery before starting the machine connections After completing the machine connections the boom can not be moved until the installation is complete Step Description Diagram...
  • Page 36 Step Description Diagram Locate connector C234 in the set of connectors on the harness running to the steering wheel switches under the dashboard panel. Cut the blue wire #3310 and join the violet wire from the CAN I/O module to the wire running to the steering wheel switches.

  • Page 37: Table 14: Machine Connections

    Step Description Diagram Connect the male spade terminal from the power harness to the female spade terminal on the CAN I/O module harness for the ground connection. View from under the joystick plate cover. Table 14: Machine Connections DO001547 VER: 2303241610 37 of 58...

  • 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. Step Description Diagram Connect the CCIM and signal light cables to the M12 connectors on the CCIM.
  • Page 39 Step Description Diagram Connect the 2 pin connector from the CAN I/O module harness into the IO harness. Connect the 4 pin connector from the CAN I/O module harness into the IO harness. Connect the 6 pin connector from the machine cutout harness to the IO harness.

  • Page 40: Table 15: Cabin Loom Installation

    Step Description Diagram Run the cables through snake tube. Cable tie to the tube running to the LMI. Connect into the 8 pin and 5 pin connectors into the display Connect the spade lug on the black wire to the negative (black) battery terminal on the backup battery.
  • Page 41 If the clip-on ferrites were removed from the CCIM and user control cables. See Appendix B: Reattach Ferrites and page 55 for the correct reattachment position. DO001547 VER: 2303241610 41 of 58...

  • Page 42: Finalisation

    Finalisation This section will complete the final power connections to power the system and finish any additional items. Step Description Diagram Connect the 3 pin connector from the radio power harness into the power/camera harness. Coil up and store the wire harnesses under the dashboard.
  • Page 43 Step Description Diagram Reconnect the tee connectors back into the spool assembly and the lock pin cable through boom connection. Note: Make sure the connections for the cable through boom are placed behind the hydraulic pipes so as not to get crushed against the rear cover once installed.

  • Page 44: Table 16: Finalisation

    Step Description Diagram Operate the boom movement controls to test if a false N07 fault occurs. If a N07 fault does occur, adjust the arm on the stow switch forwards towards the stow switch trigger. Note: The actual switch arm orientation may differ from the picture.

  • 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 17: 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 DO001547 VER: 2303241610 48 of 58...
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  • Page 52: 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 53: Table 18: 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 54: 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 DO001547 VER: 2303241610 54 of 58...

  • Page 55: 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 56: 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 57: Indexes And Tables

    Indexes and Tables Illustration Index Illustration 1: Machine Boom..................8 Illustration 2: Machine Chassis..................9 Illustration 3: Cable Reeler Mounting Position............16 Illustration 4: Damaged Display Connector..............54 Illustration 5: Do Not Use Tools To Tighten Connector...........54 Illustration 6: Do Not Over Tighten Nuts..............55 Index of Tables Table 1: Component Installation Index................6 Table 2: Cable Installation Index..................7...
  • Page 58 __________________________________________________________________________________ Equipment Safety Systems Pty. Ltd. Tel: +61 3 8770 6555 ABN: 31 061 789 151 75 Naxos Way, Keysborough 3173, Victoria, Australia Fax: +61 3 8770 6590 Web: www.eqss.com.au DO001547 VER: 2303241610 58 of 58...

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