eqss Gen-3 LMS User manual

EQUIPMENT SAFETY SYSTEMS PTY LTD
eqss™ Gen-3 LMS
Telehandler Load Management System
Installation Manual for Privilege MT18 0 Standard
Manual Tool Recognition
PLEASE NOTE:
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***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.
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provided only for your onvenien e and may be superseded by updates.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, 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.....................................................................................6
Installation Index...........................................................................................................7
overs.........................................................................................................................12
able Reeler Installation.............................................................................................14
able Reeler Mounting Position.............................................................................17
Pressure Sensor Installation.......................................................................................18
Pressure Manifold...................................................................................................18
ompensation Pressure Sensors............................................................................20
Reverse amera..........................................................................................................21
utout able Harness.................................................................................................23
Forward amera..........................................................................................................26
Stabiliser able Harness.............................................................................................28
Signal Light Installation..............................................................................................29
Machine Input Harness...............................................................................................31
an Pressure Input Module ( PIM)............................................................................32
External able ompletion.........................................................................................33
Display Installation......................................................................................................35
User Input ontrol.......................................................................................................36
an abin Interface Module ( IM)...........................................................................37
abin Loom..................................................................................................................38
Finalisation..................................................................................................................41
Set Time & Sensor alibration...................................................................................45
Schematics...................................................................................................................48
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Appendix A: Attaching Display onnectors...............................................................51
Indexes and Tables.....................................................................................................55
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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 Signal Light
7 Rear amera
8 an abin Interface Module ( IM)
9 Display Module
10 User ontrol Dial
11 Stabiliser onnections
12 Joystick (X67)
13 utout
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 Signal Light able
Aqua Rear amera able
Dark Purple IM able
Yellow/Green utout/Platform able Harness
Brown Machine Input Harness
Dark Yellow Stabiliser Harness
Red Display able
Orange User Input ontrol able
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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Illustration 3: Front of Machine
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Covers
Remove the following overs before starting the installation
Step Description Diagram
1. Remove the top 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 connections
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Step Description Diagram
4. Remove the cover behind the cabin
5. Inside the cabin remove the
dashboard display.
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. Drill and tap the holes for the cable
reeler according to the mounting
diagram on page 17.
Mount using the supplied
M6 x 16 mm 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.
Note: Ensure the anchor 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.
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Step Description Diagram
3. Drill and tap the M6 holes for the
stow switch trigger bracket.
Mount the stow switch trigger
bracket using the supplied M6 x 12
mm bolts and washers.
Adjust the length of the trigger plate
to ensure the stow switch is pressed
when the boom is retracted.
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
towards the cabin and insert into
snake tube with the reverse camera
cable during External able
ompletion on page 33.
Table 4: Cable eeler Installation
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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 4: Cable eeler Mounting Position
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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 snake tube and cables
towards the cabin and cable tie with
the other cables during External
able ompletion on page 33.
Table 5: Pressure 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 sensor with the
U shaped hydraulic connection into
the rod of the compensation cylinder
View from behind the cabin towards
the rear of the machine
2. Install the head compensation
pressure sensor into 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 snake tube and cables
towards the cabin and cable tie with
the other cables during External
able ompletion on page 33.
View from under the boom towards
the rear of the machine
Table 6: Compensation Pressure Sensor Installation
For further details on running the pressure sensor cables
refer to the Installation Index on page 7
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