eqss Gen-3 LMS User manual

EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for T40180
VER: 1906121521
Failure To Follow Installation Manual Will Void Warranty
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.

Documentation Conventions
The list below highlights important do umentation onventions.
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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.

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provided only for your onvenien e and may be superseded by updates.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, IT'S 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.....................................................................................5
Installation Index...........................................................................................................6
overs.........................................................................................................................10
able Reeler Installation.............................................................................................12
able Reeler Mounting Position.............................................................................16
Pressure Sensor Installation.......................................................................................17
Pressure Manifold...................................................................................................17
ompensation Pressure Sensors............................................................................19
Reverse amera..........................................................................................................21
an Pressure Input Module ( PIM)............................................................................23
Signal Light Installation..............................................................................................24
Stabiliser onnections................................................................................................27
Forward amera..........................................................................................................28
External able ompletion.........................................................................................30
Display Installation......................................................................................................33
User Input ontrol.......................................................................................................35
an abin Interface Module ( IM)...........................................................................36
Machine onnections..................................................................................................37
abin Loom..................................................................................................................40
Finalisation..................................................................................................................43
Set Time & Sensor alibration...................................................................................46
Schematics...................................................................................................................49
Appendix A: Attaching Display onnectors...............................................................53
Appendix B: Reattach Ferrites...................................................................................57
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Indexes and Tables.....................................................................................................58
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
◦6.8 mm
◦8.5 mm
•Centre pun h
•Tap T-Handle
•Taps
◦M6
◦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
•Torque Wren h
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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 utout onnection
6 Lock Pin Release onnection
7 Forward amera
8 Signal Light
9 Rear amera
10 Stabiliser Switches
Table 1: Component Installation Index
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olour able Description
Light Purple Boom able
Dark Green Main ylinder Pressure Sensor ables
Dark Blue ompensation ylinder Pressure Sensors ables
Red utout Harness
Orange Lock Pin Release Harness
Light Green Forward amera able
Brown Signal Light able
Light Blue Rear amera able
Dark Purple IM able
Dark Brown 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 rear covers.
2. Remove the cover behind the cabin
3. Remove the cover in front of the
cabin behind the front left wheel.
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Step Description Diagram
4. Undo the bolts attaching the
dashboard.
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.
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. Ensure the stow switch
arm is correctly adjusted to prevent this error.
When mounting the cable anchor ensure it is mounted on the
first extendable section not on the last section. If mounted on
the last section the cable reeler will be damaged when the
boom is extended.
Step Description Diagram
1. Weld the cable reeler mounting
brackets to the boom according to
the mounting diagram on page 16.
Note: After the brackets are welded
they will need to be sealed and
painted to protect against rust.
2. Drill and tap the four M6 holes to
mount the cable reeler, use the cable
reeler as a drilling template.
Mount the cable reeler to the
mounting brackets and secure using
the supplied M6 x 12 mm bolts and
washers.
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Step Description Diagram
3. 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. If
welded on the last section the cable
reeler will be damaged when the
boom is extended.
4. Drill and tap a M8 hole for the cable
anchor.
Mount the cable anchor to the
bracket and attach the cable.
5. onnect the supplied M12 10 metre
cable ( B001027) into the cable
reeler connection.
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Step Description Diagram
6. Run the cable up to the top of the
boom.
Place cable ties points down the top
of the boom as shown.
able tie the boom cable to the
cable tie points down the boom.
7. able tie to the flexible hydraulic
hoses from the end of the tube 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
towards the cabin and cable tie with
the rest of the cables during
External able ompletion on page
30.
View from behind the machine
Table 4: Cable Reeler Installation
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For further details on running the boom cable refer to the
Installation Index on page 6
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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
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 bolts and seals. Tighten
the 12.9 grade bolts for the manifold
to 41 NM using a torque wrench.
Start the machine, pressurise the
boom and check for leaks.
View from behind the machine
towards the lift cylinder
2. onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
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 snake tube and cables
towards the cabin and cable tie with
the other cables during External
able ompletion on page 30.
View from behind the machine
towards the lift cylinder
Table 5: ressure Manifold Installation
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For further details on running the pressure sensor cables
refer to the Installation Index on page 6
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Compensation Pressure Sensors
Step Description Diagram
1. 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 behind the machine
2. Undo the hydraulic connection for
the rod compensation into the
compensation cylinder.
Install the supplied tee connections
with the pressure sensors pointing
back towards the rear of the
machine.
Start the machine, pressurise the
boom and check for leaks.
View from behind the machine
3. onnect the supplied M12 4 metre
cables ( B001026) into each of the
pressure sensors.
Run the cables towards the cabin
and cable tie with the other cables
during External able ompletion on
page 30.
View from behind the machine
Table 6: Compensation ressure Sensor Installation
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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
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