Updated LSI Installation And Calibration Procedure On Certain Telehandlers {1408, 1439} Caterpillar

Telehandler

TH336 (S/N: TDE1-UP)

TH336C (S/N: THM1-UP; MJR1-UP)

TH337 (S/N: TDF1-UP)

TH337C (S/N: DJB1-UP; SXJ1-UP)

TH406 (S/N: TBX1-UP)

TH406C (S/N: RCH1-UP; GAT1-UP)

TH407C (S/N: MLH1-UP; JJT1-UP)

TH414C (S/N: KEK1-UP; RWW1-UP)

TH417C (S/N: RRJ1-UP; RRW1-UP)

TH514C (S/N: MWC1-UP; KKW1-UP)

There is an updated installation and calibration procedure for EN15000 machines with LSI display version 1.09 and above. The updated procedure has added clarity and ensures correct functionality of the LSI system. Refer to the procedure below for installation and calibration of your LSI display.

Removing Sensor and Cleaning Mounting Surface

Position machine on a firm and level surface, where it can remain stationary for at least 2 hours. Ensure that the frame is level using the level in the cab. Ensure that all wheels are in a straight-line configuration and NOT in any degree of turn.

1. Fully retract and fully raise the boom to the maximum angle. Turn off the engine, apply the park brake, and remove the key. Tag the machine "Out of service, Do not operate". Place wheel chocks in front of and behind the rear wheels.
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   Illustration 1	g03865556
   View of LSI sensor (A) LSI Sensor (B) SN213 Connect

2. Locate and unplug SN213 (B) and the existing Load Stability Indicator (LSI) sensor (A) from the cable coming from the rear frame Harness, on top of the rear axle, on the cab side of the machine. Retain the cable clamp for reinstallation.

3. Remove the bolts securing the sensor to the axle. If necessary, gently tap on the sides of the sensor to break the bond with the axle. Discard and destroy the original sensor and mounting hardware. If present, remove any residual sealant in the sensor mounting area of the axle.

4. Use a cleaner tool to remove any adhesive and or rust.

5. Ensure the threads in the axle for the sensor's retaining bolts are clean, free from rust, water, adhesive, paint, or other residual debris. If necessary, thread an M10 plug tap through the bolt holes to ensure clean threads. Remove any debris out of holes if any thread cleaning has been completed.

6. Using a suitable degreasing agent LOCTITE® 7063, clean any residual adhesive, paint, dirt, debris, and so on, from the threaded mounting holes, and the sensor mounting surface on the rear axle. Only use the amount of degreasing agent necessary for cleaning the mounting surface. Remove any residual degreasing agent that remains on the mounting surface or bolt holes.
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   Illustration 2	g03866029
   View of clean LSI sensor

7. Inspect the bottom of the LSI sensor to ensure cleanliness equal to that of the mounting surface.

   Note: FOR THE LSI SYSTEM TO FUNCTION PROPERLY, IT IS NECESSARY THAT THE SURFACE ON THE AXLE IS PERFECTLY CLEAN, FLAT, WITHOUT IRREGULARITY, PROTRUSIONS, OR DIFFERENCES OF LEVEL.

Sensor installation

Note: USE ALL APPLICABLE SAFETY PRECAUTIONS WHILE WORKING ON, UNDER OR AROUND THE MACHINE.

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Illustration 3	g03866030
View of Initiator No. 1 application

1. Sparingly apply Initiator No.1 (may also be denoted as Initiator No. 5) to each of the sensor's metallic mounting pads as shown above.
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   Illustration 4	g03866034
   View of Loctite application

2. Apply a 3 mm (.12 inch) bead of non-expired Loctite adhesive A2460 (F246) to each axle surface area, around each of the mounting holes.
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   Illustration 5	g03866036
   View of spreading Loctite

3. Use a spatula to evenly distribute the adhesive over each axle surface area. Use the following sequence to minimize the amount of adhesive entering into the threaded holes.

   1. Position the spatula over the center of the threaded hole.

   2. Move the spatula for the center of the hole to the left. Remove the excessive adhesive on the spatula.

   3. Position the spatula over the center of the threaded hole.

   4. Move the spatula for the center of the hole to the right. Remove the excessive adhesive on the spatula.

   5. Repeat steps for the other remaining hole.
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   Illustration 6	g03866044
   View of sensor installation

4. Install the 452-7079 Sensor onto the mounting surface of the axle. Ensure the electrical lead exits the sensor in the corner direction, similar to the original sensor.
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   Illustration 7	g03866055
   View of torquing the bolts

5. Insert two 454-3968 Bolts and tighten in the following sequence:

   1. Tighten each bolt "finger tight".

   2. Tighten each bolt to a torque setting of 30 ± 5 N·m (22 ± 4 lb ft).

   3. Tighten each bolt to a torque setting of 70 ± 10 N·m (52 ± 7 lb ft).

6. Scribe a permanent mark from bolt head onto sensor.
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   Illustration 8	g06007872

7. Apply black silicone sealant (Soudal Silirub 2 (Black)) around the sensor.

   1. Position the nozzle underneath the harness lead, apply a large bead around the sensor.

   2. Ensure that you end with your nozzle over the starting point.

8. Make a clean smooth finish, using a spatula and soap water.

9. STOP!

   Note: IT IS IMPERATIVE THE AXLE AND SENSOR ARE NOT STRESSED DURING THE BONDING TIME. DO NOT DRIVE THE MACHINE FOR ONE HOUR AFTER INSTALLING THE SENSOR.

10. After a minimum 1 hour of stationary cure time, the machine may be driven.

11. Connect the new sensor to the same location in the cable coming from the control unit as the original, and secure into place with the original cable clamp.

Display Replacement

1. Locate the Load Stability Indicator display inside the cabin.

2. Unscrew and disconnect the existing display.

3. Confirm that the new display has the latest software P1.10 or newer and install the LSI display.

4. Continue and perform the calibration procedure as described on the following pages.

Calibration Procedures

Note: REVIEW EACH OF THE PROCEDURE DESCRIBED BELOW TO DETERMINE WHICH IS MORE FEASIBLE FOR THE MACHINE AT HAND. PERFORM ONLY ONE OF THE ENCLOSED PROCEDURES.

• Procedure A requires the use of a calibrated scale (portable scales are acceptable) and the availability of a test weight of up to 3000 kg (6614 lb), depending on model. This is considered the Standard LSI Calibration.

• Procedure B can be accomplished in the field, requiring a test weight of up to 3000 kg (6614 lb), depending on model. This is considered the LSI Field calibration. No scales are required for accomplishment of this procedure.

Procedure A Standard Calibration

To calibrate the LSI, certain conditions must be met:

• The sensor must be installed according to the above described procedure.

• The machine control system must be powered on for at least 3 minutes before calibration.

• The operator must remain in the cab.

• The calibration shall be conducted with the standard carriage and forks attached and weights as necessary (a range of 60 - 80% of maximum weight capacity).

• The machine must be on a level surface with the wheels steered straight and park brake off, with straight driving over a distance of at least 2 m (6.5 ft) being the last movement before entering a calibration point.

• While utilizing the LSI override button, ten times lift and lower the boom stopping suddenly to induce the rear axle to bounce.

• Position the rear tires centrally on the scales.

• The calibration must be completed within 30 minutes after starting procedure.

1. Start and position the machine to perform the calibration procedure.

2. Remove the standard carriage and weight assembly.
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   Illustration 9	g03866115
   View of boom fully retracted and outriggers fully down

3. Fully retract the boom and if equipped, lower the outriggers. Shut the machine OFF.
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   Illustration 10	g03866177
   Press-Hold 'SYSTEM CHECK' until 'LED5 Orange' stops illuminating and buzzer sounds.

4. With ignition key in OFF position, press and hold SYSTEM CHECK button on LSI display and turn ignition key to engine START position. Release the ignition key when engine start is achieved, but continue to hold SYSTEM CHECK button on LSI display until the orange LED on LSI display goes out and the buzzer sounds. Release SYSTEM CHECK button.
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   Illustration 11	g03866189
   Press 'SYSTEM CHECK' when only 'LED3 Green' illuminates.

5. The LEDs will perform a rolling sequence. When only the third green LED illuminates, press the SYSTEM CHECK button. The rolling pattern will repeat if missed the first time.
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   Illustration 12	g03866201

6. The first green LED then illuminates. With no attachment, outriggers down (if equipped) and boom fully retracted, lift boom to maximum boom angle.
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   Illustration 13	g03866209

7. Press the SYSTEM CHECK button on the LSI display and release. The first three green LEDs will illuminate. The third then second green LEDs will go out as the calibration point is recorded.
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   Illustration 14	g03866228

8. The first green LED goes out and buzzer sounds then the red LED illuminates.

9. Lower boom until level. If equipped, fully raise outriggers. Pressing the LSI Override button may be required to lower the boom. Attach the previously removed standard carriage, forks, and weight.

10. Slowly extend the boom until the rear axle weight in Table 1 is achieved.
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    Table 1

    Model	Weight on Rear axle
    TH336	500 kg (1102 lb)
    TH337TH406 TH407	600 kg (1323 lb)
    TH414TH514 TH417	1000 kg (2205 lb)

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    Illustration 15	g03866232

11. Press the SYSTEM CHECK button on the LSI display and release. As the calibration point is recorded, buzzer sounds and the LEDs will flash and perform a sequence until all are flashing.

12. Turn ignition key to OFF. LSI is now calibrated.

13. Perform the LSI- CAN Check PT located at the end of this service magazine to finalize the calibration.

Procedure B Field Calibration

To calibrate the LSI, certain conditions must be met:

• The sensor must be installed according to the above described procedure.

• The test weight matches the model being calibrated in the table shown below.

• The calibration shall be conducted with standard carriage and forks attached to the machine.

• While utilizing the LSI override button, ten times lift and lower the boom stopping suddenly to induce the rear axle to bounce.

Note: If the test weight is not known, follow steps 1 and 2.

1. With the estimated test weight on the forks, start the machine and extend the boom horizontally until the machine starts to tip. Pressing the LSI override button may be required to reach tipping point.

2. By confirming that the machine tips at this point, the correct amount of weight is now on the forks.

3. The machine control system must be powered on for at least 3 minutes before calibration.

4. The machine must be on a level surface with the wheels steered straight, boom retracted horizontal and park brake OFF with standard carriage, forks, and test weight attached to the machine.

5. Drive the machine forward over a distance of at least 2 m (6.5 ft) before starting the calibration procedure. Select appropriate area with enough space in front of the machine.

6. Apply parking brake.

   Note: IF UNIT IS EQIUPPED WITH OUTRIGGERS PLEASE COMPLETE NEXT STEP, OTHERWISE SKIP TO STEP 8

7. Detach standard carriage including forks and test weight at a minimum distance of Xplace (3) in front of the machine. Pressing the LSI override button may be required.

8. Retract and level the boom horizontal. Fully lower the outriggers (if equipped). Pressing the LSI override button may be required. Shut engine OFF.

Field Calibration Procedure:

Note: The following procedure must be completed within 30 minutes of starting the procedure.

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Illustration 16	g03866287

1. With ignition key in OFF position, press and hold SYSTEM CHECK button on LSI display and turn ignition key to engine START position. Release the ignition key when engine start is achieved, but continue to hold SYSTEM CHECK button on LSI display until the orange LED on LSI display goes out and the buzzer sounds. Release SYSTEM CHECK button.
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   Illustration 17	g03866285

2. The LEDs will perform a sequence. When only the third green LED illuminates, press the SYSTEM CHECK button.
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   Illustration 18	g03866286

3. The first green LED then illuminates. With no attachment and boom retracted, lift boom fully.
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   Illustration 19	g03866290

4. Press the SYSTEM CHECK button on the LSI display and release. The first 3 green LEDs will illuminate. The third then second green LEDs will go out as the calibration point is recorded.
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   Illustration 20	g03866292

5. The first green LED goes out and buzzer sounds then the red LED illuminates.

6. Lower boom and fully raise outriggers (if equipped), attach standard carriage, forks, and test weight. Pressing the LSI Override button may be required to lower the boom.

7. With the boom horizontal, slowly extend or retract the boom to the distance of Xcal (2). The proper calibration weight is now on the rear axle and the LSI can now be calibrated.
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   Illustration 21	g03866293

8. Press the SYSTEM CHECK button on the LSI display and release. As the calibration point is recorded, buzzer sounds and the LEDs will flash and perform a sequence until all are flashing.

9. Shut off the engine.

Note: The following LSI-CAN Check PT procedure MUST BE performed to finalize the LSI System Calibration.

LSI-CAN Check PT

1. The machine must be on a level surface; wheels steered straight and park brake ON.

2. Start the machine.

3. Press the "C" and "OK" buttons simultaneously on the keypad or the analyzer.

4. Go to "ACCESS LEVEL 3" and press "OK".

5. Enter the proper access code (33271) and press "OK".

6. "ACCESS LEVEL 2" is now visible.

7. Go to "CALIBRATIONS" menu, press "OK".

8. Scroll to "LSI_CAN CHECK PT".

9. "SET LSI_CAN CHECK POINT", use the arrow keys to change "NO" to "YES", press "OK".

10. Follow and execute the screen instructions:

    1. "Remove Weights and Attachments", telescope in and press "OK".

    2. TH414C, TH514C and TH417(C) ONLY: "Fully deploy stabilizers", press "OK". Pressing the LSI Override button may be required

    3. "TELESCOPE IN and FULLY LIFT UP", press "OK".

    4. "STOP, WAIT ONE MINUTE", wait at least 1 minute and press "OK".

    5. "PRESS ENTER TO SET CHECK POINT", press "OK"

    6. Screen defaults back to "CALIBRATIONS: LSI_CAN CHECK POINT".

    7. Press "C" for approximate 2 seconds to return to normal display screen.

11. LSI Can Check is now complete.

12. Return machine to service.