eqss Gen-3 LMS User manual

EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for MT1030
Manual Tool Recognition
VER: 20150709
ailure To ollow Installation Manual Will Void Warranty

Documentation Conventions
The list below highlights important do umentation onventions.
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.
Text presented in this manner indicates that a failure to follow
directions could result in damage to equipment, loss of
information, bodily harm, or loss of life.
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Important Information
Information ontained in this publi ation regarding this devi e's appli ations and the like is
provided only for your onvenien e and may be superseded by updates. It is your
responsibility to ensure that the appli ation or our equipment meets with your
spe ifi ations.
EQUIPMENT SAFETY SYSTEMS MAKE NO REPRESENTATIONS OR WARRANTIES
OF ANY KIND WHETHER EXPRESS OR IMPLIED, WRITTEN OR ORAL, STATUTORY
OR OTHERWISE, RELATED TO THE INFORMATION, INCLUDING BUT NOT LIMITED
TO ITS CONDITION, QUALITY, PERFORMANCE, MERCHANTABILITY OR FITNESS
FOR PURPOSE.
Equipment Safety Systems dis laims all liability arising from this information and its use.
Use of Equipment Safety Systems’ produ ts as riti al omponents in life support systems
is not authorised ex ept with express written approval by Equipment Safety Systems. No
li enses are onveyed, impli itly or otherwise, under any Equipment Safety Systems
intelle tual property rights.
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Table of Contents
Tools Required for Installation.....................................................................................6
Installation Index...........................................................................................................7
overs.........................................................................................................................11
able Reeler Installation.............................................................................................13
able Reeler Mounting Position.............................................................................15
Pressure Sensor Installation.......................................................................................16
Pressure Manifold...................................................................................................16
ompensation Pressure Sensors............................................................................18
Reverse amera..........................................................................................................19
utout Harness............................................................................................................21
Forward amera..........................................................................................................23
Stabiliser able Harness.............................................................................................25
Light Tower Installation..............................................................................................27
Light Tower Bracket Mounting Position................................................................28
Machine Input Harness...............................................................................................29
an Pressure Input Module ( PIM)............................................................................30
External able ompletion.........................................................................................31
Display Installation......................................................................................................33
User Input ontrol.......................................................................................................34
an abin Interface Module ( IM)...........................................................................35
abin Loom..................................................................................................................36
Finalisation..................................................................................................................39
Sensor alibration.......................................................................................................42
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Schematics...................................................................................................................44
Indexes and Tables.....................................................................................................47
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Tools Required for Installation
The tools required to perform the installation of the TSS are listed below
•Pen il or Texta
•Drill
•Drill bits
◦3.3 mm
◦4.5 mm
◦5 mm
◦6.25 mm
◦6.8 mm
◦8.5 mm
•Centre pun h
•Tap T-Handle
•Taps
◦M6
◦M7 x 0.75
◦M8
•Drill and tap oil
•Metri Allen keys
•Phillips Head s rew driver
•Spanners and so kets
◦7 mm
◦10 mm
◦13 mm
•Lo ktite thread lo ker
•Side utters
•Stanely knife
•Crimpers
•Wire strippers
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Installation Index
The omponents and ables of the Gen-3 Telehandler Load Management System are
outline in the tables below. The following pages show where the omponents are installed
and the able routing.
See the appropriate manual se tion for a detailed installation des ription for ea h
omponent.
Refer to this section for any component placement or cable
routing issues
Item omponent Description
1 able Reeler
2 Main Lift ylinder Pressure Sensors
3 ompensation ylinder Pressure Sensors
4 an Pressure Input Module ( PIM)
5 Forward amera
6 Light Tower
7 Rear amera
8 an abin Interface Module ( IM)
9 Display Module
10 SPU Module
11 Stabiliser onnections
12 Joystick onnections (X43)
Table 1: Component Installation Index
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olour able Description
Yellow Boom able
Dark Green Main ylinder Pressure Sensor ables
Dark Blue ompensation ylinder Pressure Sensors ables
Light Blue Forward amera able
Violet Light Tower able
Aqua Rear amera able
Dark Purple IM able
Light Green utout Harness
Red Display able
Orange User Input ontrol able
Brown Machine Input Harness
Dark Yellow Stabiliser Harness
Table 2: Cable Installation Index
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Illustration 1: Machine Boom
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Illustration 2: Machine Chassis
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Covers
Remove the following overs before starting the installation
Step Description Diagram
1. Remove the top and lower rear
cover behind the boom.
2. Remove the side panel next to the
cabin under the boom.
3. Remove the covers under the boom.
Remove the covers over the
stabiliser pressure manifolds
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Step Description Diagram
4. Inside the cabin remove the
dashboard.
5. Remove the cover over the fluid
containers
6. Remove the cover over the SPU
behind the seat
Table 3: Cover removal
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Cable Reeler Installation
The able reeler is used to measure the boom extension to determine the maximum lifting
apa ity.
Step Description Diagram
1. Drill and tap the holes for the cable
reeler according to the mounting
diagram on page 15.
Mount using the supplied bolts and
washers.
2. Drill and tap an M8 hole for the
cable anchor. Ensure the cable
anchor is positioned so the cable
runs in line with the boom.
Mount the cable anchor and attach
the cable.
3. Drill and tap the M6 holes for the
stow switch trigger bracket.
Mount the stow switch trigger
bracket using the supplied bolts and
washers.
Adjust the length of the trigger plate
to ensure the stow switch is pressed
when the boom is retracted.
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Step Description Diagram
4. onnect the supplied M12 10 metre
cable ( B001027) into the cable
reeler connection.
5. Run the cable along the hydraulic
pipes running down the boom,
secure using cable ties every 150
mm to 200 mm.
able tie to the flexible hydraulic
hoses down to the chassis. Make
sure the cable isn't pinched or
stretched when the boom is raised
or lowered.
Run the remainder of the cable out
the hole below the lift cylinder
towards the rear of the machine and
cable tie with the other cables
during External able ompletion on
page 31.
Table 4: Cable Reeler Installation
For further details on running the boom cable refer to the
Installation Index on page 7
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Cable Reeler Mounting Position
Illustration 3: Cable Reeler Mounting osition
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Pressure Sensor Installation
The hydrauli 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.
Step Description Diagram
1. 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.
Apply the handbrake and insert
chock under wheels.
Remove the counterbalance valve on
the side of the hydraulic lifting ram.
Removing the counterbalance valve
will release the hydraulic pressure
which may result in a spray of oil.
Secure the pressure manifold using
the supplied 70 mm bolts and seals.
Tighten the bolts for the manifold to
25 NM using a torque wrench.
Start the machine, pressurise the
boom and check for leaks.
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Step Description Diagram
2. onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
Add both cables to 3 m of snake
tube. able 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.
Run the remainder of the cable out
the hole above the rear axle under
the lift cylinder towards the rear of
the machine and cable tie with the
other cables during External able
ompletion on page 31.
Table 5: ressure Manifold Installation
For further details on running the pressure sensor cables
refer to the Installation Index on page 7
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Compensation Pressure Sensors
Step Description Diagram
1. 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.
onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
Add both cables to 3 m of snake
tube.
Run the remainder of the cable out
the hole above the rear axle under
the lift cylinder towards the rear of
the machine and cable tie with the
other cables during External able
ompletion on page 31.
View from behind the cabin towards
the rear of the machine
Table 6: Compensation ressure Sensor Installation
For further details on running the pressure sensor cables
refer to the Installation Index on page 7
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Reverse Camera
The rear amera video is displayed on the s reen when the ma hine 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
1. Drill a 31mm hole in the location
shown.
Insert the camera through the hole
and adjust the angle using the
alignment washers.
2. onnect the camera power and
signal connectors to the supplied 5m
camera cable ( B001032).
Note; The white connector is not
used.
Secure the camera cable using a
single cable tie to maintain the
connector location.
Run the remainder of the cable
towards the cabin and cable tie with
the other cables during External
able ompletion on page 31.
Table 7: Reverse Camera Installation
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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
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