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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 SR626 Electric
***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***
DO001677 VER: 2407251551

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  • Page 1 EQUIPMENT SAFETY SYSTEMS PTY LTD eqss™ Gen-3 LMS Telehandler Load Management System Installation Manual for SR626 Electric ***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in this publication regarding this device's applications and the like is provided only for your convenience and may be superseded by updates.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........................... 9 Cable Reeler Installation.....................11 Cable Reeler Mounting Position................13 Pressure Sensor Installation..................14 Main Pressure Sensors...................14 Compensation Pressure Sensors................16 Reverse Camera......................18 Forward Camera......................20 Signal Light Installation....................22 Can Pressure Input Module (CPIM)................24 External Cable Completion..................25 Display Installation......................27 User Input Control.......................28 Can Cabin Interface Module (CCIM)................29...

  • Page 5: Tools Required For Installation

    Tools Required for Installation The tools required to perform the installation of the Gen3-LMS 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: Illustration 1: Machine Boom

    Illustration 1: Machine Boom DO001677 VER: 2407251551 7 of 49...

  • Page 8: Illustration 2: Machine Chassis

    Illustration 2: Machine Chassis DO001677 VER: 2407251551 8 of 49...

  • Page 9: Covers

    Covers Remove the following covers before starting the installation Step Description Diagram Remove the rear cover and disconnect the license plate light. Remove the side panel next to the cabin and the covers under the boom. Inside the cabin, remove the dashboard display cover and the switch panel.

  • Page 10: Table 3: Cover Removal

    Step Description Diagram Remove the Lmi box from the dashboard panel. Inside the cabin remove the fuse holder board protection panel located in the lower left part of the dashboard. Table 3: Cover removal DO001677 VER: 2407251551 10 of 49...

  • Page 11: 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 12: 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 and secure using cable ties every 150 mm to 200 mm. Cable tie to the flexible hydraulic hoses down to the chassis.

  • Page 13: Cable Reeler Mounting Position

    Cable Reeler Mounting Position Illustration 3: Cable Reeler Mounting Position DO001677 VER: 2407251551 13 of 49...

  • Page 14: Pressure Sensor Installation

    Pressure Sensor Installation The hydraulic pressure sensors are used to measure the lifting load of the telehandler. Main Pressure Sensors 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 15: Table 5: Main Pressure Sensor Installation

    Step Description Diagram Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors. Cable tie the head and rod pressure sensor cables 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 16: Compensation Pressure Sensors

    Compensation Pressure Sensors Step Description Diagram Locate the tee connections on the chassis where the compensation cylinder hydraulic lines tee into the tilt cylinder lines at the rear of the machine. Location of the tee connections behind the chassis Undo the hydraulic connection for the head compensation onto the run of the existing tee connector.

  • Page 17: Table 6: Compensation Pressure Sensor Installation

    Step Description Diagram Connect the supplied M12 4 metre cables (CB001026) into each of the pressure sensors. Run the snake tube and cables towards the cabin and cable tie with the other cables during External Cable Completion on page 25. Ensure the pressure sensors and cables do not collide with the boom and chassis structures and the...

  • Page 18: 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 19 Once the cable has been tied to the license plate light cable disconnect the cable 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 6 DO001677 VER: 2407251551 19 of 49...

  • Page 20: 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 21 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 DO001677 VER: 2407251551 21 of 49...

  • Page 22: 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 23: Table 9: Signal Light Installation

    Step Description Diagram Run the cable underneath the hose cover running down to the chassis. Note: It might be necessary to remove the hose cover to run the cable. Cable tie with the other cables during External Cable Completion on page 25.

  • Page 24: 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 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 25: External Cable Completion

    External Cable Completion All external cabling is completed in this step. Step Description Diagram Cable tie the pressure sensor, boom, reverse camera and signal light cables together up to the CPIM Coil up the additional cabling for the pressure sensor and boom cables and store it underneath the CPIM.

  • Page 26: Table 11: External Cable Completion

    Step Description Diagram Run the CCIM, cutout (Diesel version), signal light and camera cables up through the hole into the cabin under the dashboard for the servo command pressure indicator. Note: Only pull enough of cable through into the cabin as required, excess cable will be stored under outside the cabin under the cabin entry hole.

  • Page 27: Display Installation

    Display Installation The display shows the current safety status of the telehandler. Step Description Diagram Secure the display bracket base to the existing holes in the cabin frame using M6 X 20mm screws. Insert the supplied mounting ball into the bracket base.

  • Page 28: User Input Control

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

  • Page 29: Can Cabin Interface Module (Ccim)

    Can Cabin Interface Module (CCIM) The CCIM connects the system into the machine electronics. Step Description Diagram Position the CCIM on top next to the fuse holder board under the steering wheel located in the left lower part of the dashboard using double sided velcro tape.

  • Page 30: 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 31: Table 15: Cabin Loom Installation

    Step Description Diagram Run the 8 pin cable from the CCIM and 5 pin cable from the user control through the gap between the window and the dashboard. Note: The plastic dashboard cover will need to be filed down to make a hole for the cables.

  • Page 32: 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 33: Table 16: Machine Connections

    Step Description Diagram Locate the connector X31 inside the dashboard LMI indicator. Cut the following wires from the LMI indicator connector X31 and join with the CAN I/O harness with the Override and Cutout signals. Secure the wire joins with electrical tape.

  • Page 34: Finalisation

    Finalisation This section will complete the final power connections to power the system and finish any additional items. Step Description Diagram Connect the 6 pin and 4 pin connectors from the CAN I/O harness into the I/O harness. Note: The 2 pin and 12 pin connectors from the I/O harness are not used.

  • Page 35: Table 17: Finalisation

    Step Description Diagram Reconnect the main battery from the isolation switch. Turn the machine onto first stage /accessories and ensure the system is activated. Adjust the display bracket for optimal viewing Set the machine into forward gear to active the forward camera. Adjust the forward camera so the front right wheel is visible.
  • Page 36 Complete the system checklist once installation has been completed. DO001677 VER: 2407251551 36 of 49...

  • Page 37: 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 38 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 39: Table 18: 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 40: Schematics

    Schematics DO001677 VER: 2407251551 40 of 49...
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  • Page 42 DO001677 VER: 2407251551 42 of 49...

  • Page 43: 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 44: Table 19: 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 45: 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 DO001677 VER: 2407251551 45 of 49...

  • Page 46: 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 47: 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 48: Indexes And Tables

    Indexes and Tables Illustration Index Illustration 1: Machine Boom..................7 Illustration 2: Machine Chassis..................8 Illustration 3: Cable Reeler Mounting Position............13 Illustration 4: Damaged Display Connector..............45 Illustration 5: Do Not Use Tools To Tighten Connector...........45 Illustration 6: Do Not Over Tighten Nuts..............46 Index of Tables Table 1: Component Installation Index................6 Table 2: Cable Installation Index..................6...
  • Page 49 __________________________________________________________________________________ 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 DO001677 VER: 2407251551 49 of 49...

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Sr626 electric

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