EN15000 – Service Manual
Contents
1. s 8515 gt LSI DETECTED BUT NOT CONFIGURED ST The UGM has detected the LSI System is connected but not PM 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 nd _ u correct the configuration selection under the MACHINE SETUP rs Eg EE menu NO Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS G NN EN15000 Error Code 8516 8517 8516 gt LSI LOAD CELL A OUT OF RANGE AND OR 8517 gt 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 calibration2. Reset Point Reset Point LMI CAN Trip Point LSI Low Ramp to High Speed Percentage Debounce Time Percentage of Load Speed Current Time Tele TELE High Speed Current Fully Retracted EN15000 PASSIVE TH336 amp TH406 1600 mA TH337 amp TH407 1600 mA Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EE EE EN15000 Settings TH414 TH514 amp TH417 LSI High Speed LSI Low Speed LSI Creep Speed Ramp to High Rear Axle Evaluation EE NN SR a EK XN Time x TH44 1810mA doma 950 3osee 205 Reset Point Reset Point LMI CAN Trip LSI Low Speed Ramp to High Speed Percentage Debounce Time Point Percentage Current TELE Time TELE OUT of Load OUT TH417 1300 mA High Speed Current Fully Retracted EN15000 PASSIVE TH414 1600 mA TH514 1600 mA TH417 1600 mA Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Rear Axle Evaluation Time Rear Axle Evaluation Time starts after each initial joystick Output Current movement greater than LSI Low Speed J oystick Deflection we m ape s m e Y Ramp Up Time p cem Rear Axle Evaluation Time Time Example TH414 LSI High Speed Current 1310mA LSI Low Speed Current z 1110mA 0 Joystick Deflection 0mA Output Demand 100 Joystick Deflection 1310mA Demand lt 85 Joystick Deflection No evaluation Time Example 1310mA x 80 1048mA NOTE FIGURES AND GRAPHS J
3. fully retracted and without load when you take the measurements Caterpillar Confidential Green BUILDING CONSTRUCTION 50 10 mA PRODUCTS EN15000 Sensor and Harness Testing POSITIVE 12V loop between 50 10mA p n1 6 4 BLACK CELL 1 VE 6 BLUE CELL VE 8 ORANGE 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 Create a loop of the 12 Volt line between pin 1 and 6 of connector GD84 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 Ensure the machine is on level ground tires straight and the boom down fully retracted and without load when you take the measurements Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS s i EN15000 Error Code 2560 2560 gt 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 I The UGM has detected one of the following failures of the boom SOL PUO retract sensor whe
4. Axle Unloaded Moment Percentage Push C OK for 2 seconds to enter analyzer menu MENU DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DRIVE STEER CABIN JOYSTICK CABIN FUNCTIONS ENGINE SYSTEM LOAD MOMENT BOOM RIDE DRIVE DIRECTION CABIN JOYSTICK RESPONSE CURVE OPERATING STATE GROUND MODULE LOAD MOMENT BOOM RIDE INPUT FORWARD X AXIS 0 TELEHANDLER ENGINE STOPPED VOLTAGE XX XV STATUS STABLE SWITCH LOW GEAR SELECTION CABIN JOYSTICK ENGINE PREHEAT PLATFORM MODULE LOAD MOMENT BOOM RIDE INPUT 2 X AXIS NEUTRAL SWITCH OPEN VOLTAGE XXXV OVERRIDE NO STATUS OFF DIRECTION GEAR CABIN JOYSTICK MAIN LIFT AMBIENT LOAD MOMENT 96 ACTUAL FORWARD 2 Y AXIS 0 COMMANDED TEMPERATURE XXXC XX X DESIRED STEER CABIN JOYSTICK STATION CONTROL MOMENT CELL1 RAW MODE 2 WHEEL Y AXIS NEUTRAL CABIN VALUE XXXXXX CURRENT STEER CABIN JOYSTICK TELESCOPE COOLANT OPERATING MODE MOMENT CELL RAW MODE 2 WHEEL L ROLLER 0 INPUT XXX TEMPERATURE XXXC CABIN MODE VALUE 200000 STEER PRESSURE CABIN JOYSTICK TELESCOPE OIL PRESSURE RESPONSE CURVE SWITCH OPEN L ROLLER NEUTRAL COMMANDED XXXX PSI TELEHANDLER STEER PRESSURE CABIN JOYSTICK STATUS OK R ROLLER 0 TELESCOPE AMBIENT PLATFORM STATUS ACTUAL XXXXMA TEMPERATURE XXXC NOT ATTACHED SERVICE BRAKE CABIN JOYSTICK FORK TILT J1 21 PLATFORM Caterpillar Confidential Gre
5. TH337 amp TH407 Standard on Platform Machines Stabilizer amp Boom Angle Operation Limitations TH414 TH514 amp 417 Optional and or Country Spec Caterpillar Confidential Green e Fully Retract Switch EN15000 e Requirements Standard on all models now e Platform Machines Stabilizer amp Boom Angle Operation Limitations e EN15000 Passive BUILDING CONSTRUCTION PRODUCTS EN15000 Components e LSI Display LSI Display Machine ON status small green Machine lifting a load axle unloaded LED in the System Check button moment between 50 89 9 e 1 green LED 50 59 9 green LED 60 69 9 3 d green LED 70 79 9 4 green LED 80 89 9 SYSTEM SYSTEM CHECK CHECK Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS 15000 Components e LSI Display LSI Display Amber LED on the rear axle Red LED on the rear axle unloaded unloaded percentage nearing trip percentage trip point 100 rated point but still within operable range capacity has been met or 90 99 9 If the amber LED comes exceeded All LED s will flash on the LED s will flash simultaneously and a continuous simultaneously and an intermittent audible alarm will sound All audible alarm will sound aggravating movements are cut out EDS SYSTEM CHECK BUILDING CONSTRUCTION PRO
6. DUCTS EN15000 Fully Retracted Passive All Models TH336 TH337 TH406 amp H407 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 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Passive Mode TH336 TH337 TH406 amp TH407 4 sy p 15000 ih PASSIVE AND EN15000 PASSIVE AND EN15000 ACTIVE 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 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS ii EN15000 Settings Explanation e LSI High Speed Current Max mA setting for boom down movement e LSI Low Speed Current Max mA setting for boom down movement when axle load percentage meets or exceeds 70 after evaluation period e LSI Creep Speed Current Max mA setting for boom down movement when axle load percentage meets or exceeds 70 during evaluation
7. EN15000 Service Manual October 2011 BUILDING CONSTRUCTION PRODUCTS CATERPILLAR Caterpillar Confidential Green TODAY S WORK TOMORROW S WORLD EN15000 Affected Serial Number Range TH336 gt S N TDE00337 amp After including TDE00297 318 328 amp 332 H337 gt S N TDF00297 amp After including TDF00297 299 302 317 320 321 323 324 amp 327 406 gt S N TBX00454 amp After TH407 gt S N TBY01110 amp After excluding 01121 1122 amp 1128 TH414 gt S N TBZ00561 amp After 514 gt S N TBW00201 amp After TH417 gt S N TBT00216 amp After Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 LSI System Explanation Introduction European CE telehandlers will be expected to comply with new regulations pertaining to the machine s load moment or rear axle 5 moment sensing system The intention of the new regulation is to prevent longitudinal forward instability from occurring by reducing the machine 5 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 315 2010 shall comply with the requirements of EN15000 2008 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 LSI System Explanation Requirements EN15000 complian
8. ING CONSTRUCTION PRODUCTS Boom Down TH414 1800 Rear Axle KAN Lee 5 leto nn IO e iano plinti Output Current MA LSI High Speed EN15000 Active 1310 EE aoe 1110 LSI Low Speed EN15000 Active LSI Low Speed 15000 Active 0 2 sec 5 sec I M Time i Ramp Up Tim Eval Time NOTE FIGURES AND GRAPHS JUST AS REFERENCE FULL JOYSTICK DOWN DEFLECTION Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS _ Boom Down 1H414 1800kg 3 0m Extension x IV 2 __ 3 1 ri m x w a r Se 3 _ E ER gt gt gt gt rt _ E 1 reo a lt um Rear Axle KAP Le Time Output Current mA LSI High Speed EN15000 Active 1310 4242645554422 1110 LSI Low Speed EN15000 Active Aggravating Movements Locked Out O 5 sec 2 sec Ramp Up Tim I I I I I I I I I I I I LSI Low Speed 15000 Active I I I I I I I me I Eval Time NOTE FIGURES AND GRAPHS JUST AS REFERENCE FULL JOYSTICK DOWN DEFLECTION Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Components Rear
9. If the torque setting is correct replace the LSI sensor and perform a field calibration Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS G NN EN15000 Error Code 8516 8517 8516 gt LSI LOAD CELL A OUT OF RANGE AND OR 8517 gt 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 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Error Code 8518 Caterpillar Confidential Green 8518 gt LSI CUTOUT OUTPUT SHORT TO BATTERY OR OPEN CIRCUIT LSI System s digital output is not responding as expected The LSI System is reporting
10. UST AS REFERENCE Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS 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 I I I lt I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Rear Axle Load 96 100 85 70 bdc Time Output Current mA High 1310 J Low 1110 4 Creep 950 I Scenario 1 Scenario 2 2 sec O 2 sec Time lt gt Eval Time Eval Time Example TH414 LSI Low Speed Current 1110mA LSI Creep Speed Current 950mA NOTE FIGURES AND GRAPHS JUST AS REFERENCE Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS rr_ _ _t EN15000 Overload Condition e 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 ELE Rear Axle Load 90 gt TH336 TH406 TH337 amp TH407 a O e Rear Axle Load 85
11. e 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 BUILDING CONSTRUCTION PRODUCTS EN15000 Error Code 99151 99151 gt 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 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS _ r r EN15000 Error Code 99152 e 99152 gt LSI FAULTY SYSTEM FLASH CRC ERROR The LSI System has an internal error e Replace the LSI Display and perform the field calibration procedure Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS _ r r EN15000 Error Code 99153 99153 gt LSI FAULTY DATA FLASH CRC ERROR The LSI System has an internal error Replace the LSI Display and perform the field calibration procedure Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS _ r r n EN15000 Error Code 99154 99154 gt LSI FAULTY LOAD CELLS A AND B DISAGREEMENT 10 sensing current difference between load cells The LSI System is reporting it is seeing a 10 sensing current difference between the load cells In the majority of cases this is typically caused by a w
12. en BUILDING CONSTRUCTION PRODUCTS EN15000 Electrical Overview LSI DISPLAY CAT TH SERIES EN15000 LSI SYSTEM WIRING DIAGRAM LSI SENSOR PINOUT LSI SENSOR LIL SEED G e e e e jG G G ta fo 11 Ol 9 m k POWER DISTRIBUTION BOARD la 15 EI TF h TH x 4 J i T 4 T3 ers 1 T on 28 L i RT i SIT ON e ru ENER semi F23 10A i Pa EN rr ST a 1 1 TF EA o EY CONNECTOR XL E INPUT SIGNAL BOOM RETRALT Caterpillar Confidential Green J7 TO GU OUT BUILDING CONSTRUCTION BAIT PROK BOOM RETRACT PRODUCTS EN15000 Sensor Testing COLOR DESCRIPTION B sue me MA s To check both cells of the LSI Sensor connector SN213 of the LS 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 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
13. gt TH414 514 amp TH417 b LED s 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 e Reset Point Debounce Time 1 second gt TH336 TH406 TH337 amp TH407 x Reset Point Debounce Time 1 5 second gt TH414 TH514 amp 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 A WARNING TIP OVER HAZARD Exceeding lift capacity of the telehandler could damage the equipment and or cause tip over Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS Boom Down TH414 1800kg Fully Retracted N 1 Rear Axle Load 96 Output Time Current mA 1600 High Speed EN15000 Passive Time NOTE FIGURES AND GRAPHS JUST AS REFERENCE FULL JOYSTICK DOWN DEFLECTION Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS Rear Axle Load 96 Time Output Current mA LSI High Speed EN15000 Active 2 sec 5 sec Ramp Up Time Eval Time NOTE FIGURES AND GRAPHS JUST AS REFERENCE FULL JOYSTICK DOWN DEFLECTION Time Caterpillar Confidential Green BUILD
14. iring 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 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS ge EN15000 Field Calibration Procedure Go to Section 9 16 of Service Manual 31200370 Rev F or later Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS
15. n configured for LSI CAN or LSI CAN LMI rrr gt T i ACK With no telescope functions active boom retract sensor state change occurs after a 1000ms telescope function state change expires With TELESCOPE IN active a boom retract sensor transition of i HIGH to LOW occurs after a 1000ms telescope function state With TELESCOPE OUT active boom retract sensor transition of LOW to HIGH occurs after a 1000ms telescope function state ati Tr change expires Son nor With TELESCOPE OUT active the boom retract sensor has not N HIGH for a period of 5 seconds with at least 950mA commanded Va 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 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Error Code 8514 8514 gt LSI NOT CALIBRATED L SI 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 LS System has successfully been calibrated Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Error Code 8515 OF A OL
16. period e 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 e 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 e Reset Point Percentage Rear axle load percentage point to reset overload condition e 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 e LSI Low Speed Current TELE Max mA setting for TELE OUT movement when axle load percentage exceeds 70 after evaluation period e 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 e High Speed Current EN15000 passive Max mA setting for boom down movement when the boom is fully retracted and so the EN15000 LSI system is passive Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Settings TH336 TH337 406 amp 407 LSI High LSI Low Speed LSI Creep Speed Ramp to High Rear Axle Evaluation Speed Current Current Current Speed Time Time TH336 amp TH406 1580 mA 1070 mA 900 mA TH337 amp TH407 1580 mA 1110 mA 900 mA
17. t 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 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS 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 EN15000 Components LSI Display 15000 LSI Display 15000 CAT P N 312 3331 CAT P N 377 9838 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Components e LSI Sensor PRE EN15000 e LSI Sensor EN15000 CAT P N 320 9370 CAT P N 382 8745 Caterpillar Confidential Green BUILDING CONSTRUCTION PRODUCTS EN15000 Components Fully Retract Switch PRE EN15000 TH406 e Requirements Not available on TH336 TH406
18. 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 f 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 BUILDING CONSTRUCTION PRODUCTS EN15000 Error Code 8519 Caterpillar Confidential Green 8519 gt 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 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 b
Download Pdf Manuals
Related Search