EN15000 - Service Manual

EN15000 Service Manual
March 2011
B U I L D I N G
Caterpillar: Confidential Green
C O N S T R U C T I O N
P R O D U C T S
EN15000 Affected Serial Number Range

TH336 S/N TDE00337 & After (including TDE00297-318, 328 & 332)
TH337 S/N TDF00297 & After (including TDF00297, 299-302, 317, 320, 321, 323, 324 & 327)
TH406 S/N TBX00454 & After
TH407 S/N TBY01110 & After (excluding TBY01121, 1122 & 1128)
TH414 S/N TBZ00561 & After
TH514 S/N TBW00201 & After
TH417 S/N TBT00216 & After

2
B U I L D I N G
P R O D U C T S
EN15000 LSI-System Explanation

Introduction:
European (CE) telehandlers will be expected to comply with new
regulations pertaining to the machines load moment or rear axles
moment sensing system. The intention of the new regulation is to prevent
longitudinal (forward) instability from occurring by reducing the machines
function speeds before the 100% axle unloaded cutout point is reached.
These new regulations are part of the European Standard EN15000:2008.
Effective:
All machines produced after August 31st 2010 shall comply with the
requirements of EN15000:2008.
B U I L D I N G
P R O D U C T S
EN15000 LSI-System Explanation

Requirements:
EN15000 compliant system requires electronic control of both the static
and dynamic moments associated with load movement in the longitudinal
forward machine axis as well as the cutout of the aggravating functions.
This type of control has to be of a redundant type, and the new
components in use will allow that. The norm applies to both construction
and agricultural machines (static) and foresees that the cutout can be
overridden temporarily and also that it can be deactivated when the boom
is retracted.
Summary:
machine requires electronic control of both the static and dynamic
moments associated with load movement in the longitudinal machine axis
B U I L D I N G
P R O D U C T S
EN15000 System is NOT:
Replacement for load chart
Substitute for operator training
Protection from lateral instability risks
Protection from backward instability risks
B U I L D I N G
P R O D U C T S
EN15000 Components
LSI Display (PRE- EN15000)
CAT P/N:312-3331
LSI Display (EN15000)

CAT P/N:368-2822
B U I L D I N G
P R O D U C T S
EN15000 Components
LSI Sensor (PRE EN15000)
CAT P/N:320-9370
LSI Sensor (EN15000)

CAT P/N:368-2823
B U I L D I N G
P R O D U C T S
EN15000 Components
Fully Retract Switch
(PRE EN15000)
TH406
TH417
Requirements:
Not available on TH336, TH406, TH337 &
TH407
TH406
TH417
Requirements:
Standard on all models now
Platform Machines
Standard on Platform Machines
Stabilizer & Boom Angle Operation

Limitations
Stabilizer & Boom Angle Operation

Limitations
EN15000 Passive
Fully Retract Switch (EN15000)
TH414, TH514 & TH417 Optional and/or

Country Spec
B U I L D I N G
P R O D U C T S
EN15000 Components
LSI Display
Machine ON status, small green
LED in the System Check button.
LSI Display
Machine lifting a load, axle unloaded
moment between 50 89.9%
1st green LED: 50-59.9%
2nd green LED: 60-69.9%
3rd green LED: 70-79.9%
4th green LED: 80-89.9%
B U I L D I N G
P R O D U C T S
EN15000 Components
LSI Display
Amber LED on; the rear axle
unloaded percentage nearing trip
point, but still within operable range
90-99.9%. If the amber LED comes
on, the LEDs will flash
simultaneously and an intermittent
audible alarm will sound.
10
LSI Display
Red LED on; the rear axle unloaded
percentage trip point (100% rated
capacity) has been met or
exceeded. All LEDs will flash
simultaneously and a continuous
audible alarm will sound. All
aggravating movements are cut out.
B U I L D I N G
P R O D U C T S
EN15000 Fully Retracted Passive (All Models)
TH336, TH337,
TH406 & TH407
TH414
TH514
TH417
Boom Fully Retracted:

- Sensor in the back of the boom is made (J3-8 is High)
- No hydraulic cut-out, only audible and visible alarm
in case of an overload condition
- No speed reduction of boom movement
11
B U I L D I N G
P R O D U C T S
EN15000 Passive Mode TH336, TH337, TH406 & TH407

AND
EN15000
PASSIVE
AND
EN15000
PASSIVE
EN15000
ACTIVE
R
AND
/
OR
Passive Mode: The automatic function cutout and/or slow down feature is disabled, visual and
audible alarm in event of an overload condition, when the machine is in Driving Mode or when the
boom is fully retracted. No speed reduction of aggravating movement.
Driving Mode: Parking Brake NOT applied AND shifter in Forward or Reverse (if one of the conditions
is not met the system will be active)
Passive Mode Indicator: Yellow LED above the LSI display is illuminated.
12
B U I L D I N G
P R O D U C T S
EN15000 Settings Explanation

LSI High Speed Current:
Max. mA setting for boom down movement
LSI Low Speed Current:
Max. mA setting for boom down movement when axle load percentage
meets or exceeds 70% after evaluation period
LSI Creep Speed Current:
Max. mA setting for boom down movement when axle load percentage
meets or exceeds 70% during evaluation period
Ramp to High Speed Time:
Required time to ramp up from LSI LOW Speed Current to LSI

High Speed Current for boom down after the evaluation period
Rear Axle Evaluation Time:
Period that rear axle load percentage will be monitored after each initial
boom down request greater than LSI LOW SPEED CURRENT.
Reset Point Percentage:
Rear axle load percentage point to reset overload condition
Reset Point Debounce Time:
Period that joystick must be in neutral position after Reset Point

Percentage is passed to get max. allowed speed back (LOW or Creep
Speed) in stable condition.
LMI-CAN Trip Point Percentage of Load:
Trigger point for mA output (LOW or Creep).
LSI Low Speed Current (TELE):Max. mA setting for TELE OUT movement when axle load percentage
exceeds 70% after evaluation period
Ramp to High Speed Time (TELE): Required time to ramp up from LSI LOW Speed Current to LSI High
Speed Current for TELE OUT movement after the evaluation period
High Speed Current (EN15000 passive):
13
Max. mA setting for boom down movement when the boom is

fully retracted and so the EN15000 LSI system is passive.
B U I L D I N G
P R O D U C T S
EN15000 Settings TH336, TH337, TH406 & TH407

LSI High
Speed Current
LSI Low Speed

Current
LSI Creep Speed

Current
Ramp to High
Speed Time
Rear Axle Evaluation

Time
TH336 & TH406
1580 mA
1070 mA
900 mA
2.5 sec
1.5 sec
TH337 & TH407
1580 mA
1110 mA
900 mA
2.5 sec
1.5 sec
Reset Point
Percentage
Reset Point
Debounce Time
LMI-CAN Trip Point

Percentage of Load
LSI Low
Speed Current
(TELE)
Ramp to High Speed

Time (Tele)
TH336 & TH406
90%
1.0 sec
70%
1180 mA
1.5 sec
TH337 & TH407
90%
1.0 sec
70%
1180 mA
1.5 sec
High Speed Current Fully Retracted

(EN15000 PASSIVE)
14
TH336 & TH406
1600 mA
TH337 & TH407
1600 mA
B U I L D I N G
P R O D U C T S
EN15000 Settings TH414, TH514 & TH417

LSI High Speed
Current
LSI Low Speed

Current
LSI Creep Speed

Current
Ramp to High
Speed Time
Rear Axle Evaluation

Time
TH414
1310 mA
1110 mA
950 mA
3.0 sec
2.0 sec
TH514
1570 mA
1270 mA
950 mA
3.0 sec
2.0 sec
TH417
1330 mA
1150 mA
950 mA
3.0 sec
2.0 sec
Reset Point
Percentage
Reset Point
Debounce Time
LMI-CAN Trip
Point Percentage
of Load
LSI Low Speed

Current (TELE
OUT)
Ramp to High Speed

Time (TELE OUT)
TH414
85%
1.5 sec
70%
1180 mA
2.0 sec
TH514
85%
1.5 sec
70%
1300 mA
2.0 sec
TH417
85%
1.5 sec
70%
1300 mA
2.0 sec
High Speed Current Fully Retracted

(EN15000 PASSIVE)
15
TH414
1600 mA
TH514
1600 mA
TH417
1600 mA
B U I L D I N G
P R O D U C T S
EN15000 Rear Axle Evaluation Time

Rear Axle Evaluation Time starts after each initial joystick
movement greater than LSI Low Speed
Output Current Joystick Deflection
1310mA
1110mA
1048mA
Ramp Up Time
Rear Axle Evaluation Time
100%
80%
Scenario 2
Scenario 1
Time
Example: TH414
LSI High Speed Current = 1310mA
LSI Low Speed Current = 1110mA
0% Joystick Deflection = 0mA Output Demand
100% Joystick Deflection = 1310mA Demand
< 85% Joystick Deflection = No evaluation Time
(Example: 1310mA x 80% = 1048mA)
NOTE: FIGURES AND GRAPHS JUST AS REFERENCE!
16
B U I L D I N G
P R O D U C T S
EN15000 LSI Creep Speed Current

LSI Creep Speed Current is the max. output current in case the rear axle
unload percentage is greater or exceeds 70% during the rear axle
evaluation time.
Rear Axle
Load (%) 100
85
70
Time
Output
Current(mA)
High - 1310
Low - 1110
Creep - 950
Scenario 1
0
2 sec
Eval. Time
Scenario 2
0
2 sec
Time
Eval. Time
Example: TH414
LSI Low Speed Current = 1110mA
LSI Creep Speed Current = 950mA
17
B U I L D I N G
P R O D U C T S
EN15000 Overload Condition

Overload Condition
All Led's are flashing, continuous alarm
Hydraulic functions are locked out, except boom raise, boom retract and
hydraulic QC (Australia = boom raise also locked out).
Re-engage aggravating movements

Requirements: an a or b percentage of the rear axle load and a neutralization
of the joystick for x or y seconds.
Raise or retract the boom, rear axle load reset points after overload
Rear Axle Load 90% => TH336, TH406, TH337 & TH407 [a]
Rear Axle Load 85% => TH414, TH514 & TH417 [b]
LEDs stop blinking after return to safe condition
Joystick must be in neutral position after return to safe condition for x or y

seconds which is called the Reset Point Debounce Time.
Reset Point Debounce Time 1 second => TH336, TH406, TH337 & TH407 [x]
Reset Point Debounce Time 1.5 second => TH414, TH514 & TH417 [y]
Override the system
LSI Override Button: Momentarily disables the automatic function cut-out. LED flashes while activated. Depress and hold up to
30 seconds while operating joystick to momentarily disable the automatic function cutout.
LSI Override Button
18
B U I L D I N G
P R O D U C T S
Boom Down TH414 -1800kg Fully Retracted

BOOM FULLY RETRACTED
=
EN15000 LSI SYSTEM PASSIVE
(No cut-out, only LEDs &
audible alarm)
Rear Axle
Load (%)
100
85
70
Output
Current(mA)
1600
Time
High Speed (EN15000 Passive)
Time

19
FULL JOYSTICK DOWN DEFLECTION

B U I L D I N G
P R O D U C T S
Boom Down TH414 -1800kg 0.5m Extension
Rear Axle
Load (%)
100
85
70
Time
Output
Current(mA)
LSI High Speed (EN15000 Active)
1310
1110
LSI Low Speed (EN15000 Active)
2 sec
5 sec
Time
Ramp Up Time
Eval. Time
20

B U I L D I N G
P R O D U C T S
Rear Axle
Load (%) 100
85
70
Time
Output
Current(mA)
1310
1110
2 sec
5 sec
Time
Ramp Up Time
Eval. Time
21

B U I L D I N G
P R O D U C T S
Rear Axle
Load (%) 100
85
70
Time
Output
Current(mA)
1310
1110
Aggravating Movements Locked Out
2 sec
5 sec
Time
Ramp Up Time
Eval. Time
22

B U I L D I N G
P R O D U C T S
EN15000 - Components
Rear Axle Unloaded Moment Percentage
Push C + OK for 2 seconds
to enter analyzer menu
23
B U I L D I N G
P R O D U C T S
EN15000 Electrical Overview
24
B U I L D I N G
P R O D U C T S
EN15000 Sensor Testing
A
C
To check both cells of the LSI Sensor, connector SN213 of the

LSI sensor needs to be disconnected. The position of connector is model
specific so can be different as shown on the picture.
Supply 12 Volt to pin B of the LSI sensor connector.
Connect the COM line of the multimeter to Ground
SN213
Connect multimeter to pin A, to measure cell 1

Connect multimeter to pin C, to measure cell 2
If the current (DC) of both cells is in the range of 50mA +/- 10mA,
the sensor is working.
Ensure the machine is on level ground, tires straight and the boom down,
fully retracted and without load when you take the measurements.
25
B U I L D I N G
P R O D U C T S
EN15000 Sensor and Harness Testing

+12V loop
between
pin 1 + 6
To check both cells of the LSI Sensor and the harness towards the LSI display,
connector GD84 of the LSI Display needs to be disconnected.
Cell 1
Create a loop of the +12 Volt line between pin 1 and 6 of connector GD84.
Cell 2
Ensure the key switch is in position 1.

Connect the COM line of the multimeter to pin 2
Connect multimeter to pin 4, to measure cell 1
Connect multimeter to pin 5, to measure cell 2
If the current (DC) of both cells is in the range of 50mA +/- 10mA, the sensor is
working and the harness from the LSI sensor to the LSI display is ok.
GD84
Ensure the machine is on level ground, tires straight and the boom down,
fully retracted and without load when you take the measurements.
26
B U I L D I N G
P R O D U C T S
EN15000 Error Code 2560

2560 -> Boom Retract Sensor Faulty Sensing Invalid
The UGM has detected any information on input J3-8 Boom
Retracted is invalid or the system is set if the boom is always
extended or retracted.
The UGM has detected one of the following failures of the boom
retract sensor when configured for LSI-CAN or LSI-CAN + LMI:
With no telescope functions active, a boom retract sensor state
change occurs after a 1000ms telescope function state change
expires.
With TELESCOPE IN active, a boom retract sensor transition of
HIGH to LOW occurs after a 1000ms telescope function state
change expires.
With TELESCOPE OUT active, a boom retract sensor transition
of LOW to HIGH occurs after a 1000ms telescope function state
change expires.
With TELESCOPE OUT active, the boom retract sensor has not
HIGH for a period of 5 seconds with at least 950mA commanded
on the function AND the Load Moment Warning Point has been
met or exceeded.
Power needs to be cycled. If error code is still present, boom

retract sensor needs to be inspected for contamination and
mounting integrity.
27
B U I L D I N G
P R O D U C T S
8514 -> LSI NOT CALIBRATED

LSI System not calibrated.
The LSI System is reporting it does not have a valid calibration.
This situation should only occur at the factory and when LSI
display has been replaced in the field. This condition will be
satisfied once the LSI System has successfully been calibrated.
28
B U I L D I N G
P R O D U C T S
8515 -> LSI DETECTED BUT NOT CONFIGURED

The UGM has detected the LSI System is connected but not
configured.
The UGM is reporting the EN15000 LSI System is installed
however it has not been configured properly. The machine has
either been configured as an ANSI unit or LOAD MOMENT menu
has been set to LSI or LMI. Either remove the LSI System or
correct the configuration selection under the MACHINE SETUP
menu.
29
B U I L D I N G
P R O D U C T S
EN15000 Error Code 8516 / 8517

8516 -> LSI LOAD CELL A OUT OF RANGE
AND/OR
8517 -> LSI LOAD CELL B OUT OF RANGE
LSI System is out of range (LOW side).
The LSI System is reporting it sees one or both of the load cells
out of range on the low side of the expected operating range. In
the majority of cases, this is typically caused by a wiring issue.
Start by evaluating the wiring of the 3-pass connector at the load
cell. Next, disconnect the LSI display and perform a continuity
check of the LSI cable running from the display to the sensor. If
the wires all check out and are located in the proper connector
position, check the crimps of the respective wire in the LSI
display. Next, visually inspect the sensor for damage. Verify the
LSI Sensor is still secured to the axle at 60-70 N-m. If the bolt
turns the torque is incorrect and the machine must undergo a
field calibration. If the torque setting is correct, replace the LSI
Sensor and perform a field calibration.
30
B U I L D I N G
P R O D U C T S
EN15000 Error Code 8516 / 8517

8516 -> LSI LOAD CELL A OUT OF RANGE
AND/OR
8517 -> LSI LOAD CELL B OUT OF RANGE
LSI System is out of range (HIGH side).
The LSI System is reporting it sees one or both of the load cells
out of range on the high side of the expected operating range. In
the majority of cases, this is typically caused by a wiring issue.
Start by evaluating the wiring of the 3-pass connector at the load
cell. Next, disconnect the LSI display and perform a continuity
check of the LSI cable running from the display to the sensor. If
the wires all check out and are located in the proper connector
position, check the crimps of the respective wire in the LSI
display. Next, visually inspect the sensor for damage. Verify the
LSI Sensor is still secured to the axle at 60-70 N-m. If the bolt
turns the torque is incorrect and the machine must undergo a
field calibration. If the torque setting is correct, replace the LSI
Sensor and perform a field calibration.
31
B U I L D I N G
P R O D U C T S
8518 -> LSI CUTOUT OUTPUT SHORT TO BATTERY OR

OPEN CIRCUIT
LSI Systems digital output is not responding as expected.
The LSI System is reporting the LSI Display has determined that
a open circuit or short to battery condition exists on its output
signal pin (3). Pin 3 of the LSI Display connects to the UGM
input J4-10. In the majority of cases, this is typically caused by a
wiring issue. Start by checking the connections at both ends and
then perform a continuity check. Note, if the machine is fitted
with a 3B6 system, it also provides as parallel signal to UGM
input J4-10 and could be the cause of the issue. If everything
check out, then most likely there has been internal damage to LSI
Display and it should be replaced; then perform a LSI field
calibration procedure.
32
B U I L D I N G
P R O D U C T S

8519 -> LSI OUT OF CALIBRATION
The LSI-CAN Check Points have not been calibrated or failed a
check with the UGM.
The UGM is reporting the LSI-CAN Check Points either have not
been entered after a LSI System calibration or during the LSI
check the actual load cell raw counts are not within +/- 10 counts
of the logged calibrated counts. The most likely event is the
machine is either not on level ground or the machine is not in the
proper configuration for running the test.Also, if the UGM were to
be replaced in the field, the UGM logged LSI-CAN check points
will need to be re-entered in the CALIBRATIONS menu. Once
this has been completed, the LSI-CAN check point test in the
OPERATOR TOOLS menu will need to be performed.
The LSI System does not need to be calibrated. The UGM
just needs the information from the LSI System so the UGM
can perform the a system integrity check.
33
B U I L D I N G
P R O D U C T S
99151 -> FUNCTIONS LOCKED OUT LSI SOFTWARE

VERSION IMPROPER
The UGM has determined the LSI Display is not an acceptable
software version.
Replace the LSI Display and perform the field calibration
procedure.
34
B U I L D I N G
P R O D U C T S
99152 -> LSI FAULTY SYSTEM FLASH CRC ERROR

The LSI System has an internal error.
procedure
35
B U I L D I N G
P R O D U C T S
99153 -> LSI FAULTY DATA FLASH CRC ERROR

The LSI System has an internal error.
procedure
36
B U I L D I N G
P R O D U C T S
99154 => LSI FAULTY LOAD CELLS A AND B

DISAGREEMENT
5% sensing current difference between load cells.
The LSI System is reporting it is seeing a 5% sensing current
difference between the load cells. In the majority of cases, this is
typically caused by a wiring issue. Start by evaluating the wiring
of the 3-pass connector at the load cell. Next, disconnect the LSI
display and perform a continuity check of the LSI cable running
from the display to the sensor. If the wires all check out and
located in the proper connector position, check the crimps of the
respective wire in the LSI display. Next, visually inspect the
sensor for damage. Verify the LSI Sensor is still secured to the
axle at 60-70 N-m. If the bolt turns the torque is incorrect and the
machine must undergo a field calibration. If the torque setting is
correct, replace the LSI Sensor and perform a field calibration.
37
B U I L D I N G
P R O D U C T S
EN15000 Field Calibration Procedure
Go to Section 9.16 of Service Manual 31200370 Rev. F (or later)
38
B U I L D I N G
P R O D U C T S

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EN15000 Service Manual

Caterpillar: Confidential Green

EN15000 Affected Serial Number Range

TH406 S/N TBX00454 & After

TH414 S/N TBZ00561 & After

TH514 S/N TBW00201 & After

TH417 S/N TBT00216 & After

Caterpillar: Confidential Green

EN15000 LSI-System Explanation

Caterpillar: Confidential Green

EN15000 LSI-System Explanation

Caterpillar: Confidential Green

EN15000 System is NOT:

Replacement for load chart

Substitute for operator training

Protection from lateral instability risks

Protection from backward instability risks

Caterpillar: Confidential Green

Caterpillar: Confidential Green

LSI Display (EN15000)

Caterpillar: Confidential Green

LSI Sensor (EN15000)

Standard on Platform Machines

Stabilizer & Boom Angle Operation

Stabilizer & Boom Angle Operation

Fully Retract Switch (EN15000)

TH414, TH514 & TH417 Optional and/or

Caterpillar: Confidential Green

Caterpillar: Confidential Green

Caterpillar: Confidential Green

EN15000 Fully Retracted Passive (All Models)

Boom Fully Retracted:

Caterpillar: Confidential Green

EN15000 Passive Mode TH336, TH337, TH406 & TH407

Caterpillar: Confidential Green

EN15000 Settings Explanation

Max. mA setting for boom down movement

LSI Low Speed Current:

LSI Creep Speed Current:

Ramp to High Speed Time:

Required time to ramp up from LSI LOW Speed Current to LSI

Rear Axle Evaluation Time:

Reset Point Percentage:

Rear axle load percentage point to reset overload condition

Reset Point Debounce Time:

Period that joystick must be in neutral position after Reset Point

LMI-CAN Trip Point Percentage of Load:

Trigger point for mA output (LOW or Creep).

Caterpillar: Confidential Green

Max. mA setting for boom down movement when the boom is

EN15000 Settings TH336, TH337, TH406 & TH407

LSI Low Speed

LSI Creep Speed

Rear Axle Evaluation

TH336 & TH406

TH337 & TH407

LMI-CAN Trip Point

Ramp to High Speed

TH336 & TH406