Usage:
TH62 (3LN, 4TM),
TH63 (3NN, 5WM),
TH82 (3KN, 3JN),
TH83 (3RN),
TH103 (3PN) Telescopic Materials Handler
Description of Change: An improved adhesive is now available to bond the longitudinal stability indicator (LSI) strain sensor to the mounting blocks on the main frame. The new 154-8874 Adhesive will improve strain sensor adhesion to the blocks and reduce the possibility of the LSI Display LED's illuminating and the audible alarm sounding intermittently due to strain sensor drift.
Adaptable To: The new 154-8874 adhesive is effective with 3LN858-Up, 4TM1551-Up, 3NN976-Up, 5WM2320-Up, 3KN451-Up, 3JN653-Up, 3RN1654-Up and 3PN475-Up and is a direct replacement for the former 8T-9021 Adhesive. Adaptable to all listed machines from first production. Use the attached procedures:
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- 1. "Strain Sensor Replacement" for rebonding the sensor.
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- 2. "Field Calibration" for recalibrating of new sensor after bonding.
Strain Sensor Replacement - Type 1 And Type 2 Systems
Material Required
- Adhesive Kit 154-8874 - which contains:
- Adhesive (syringe)
- Activator (aerosol)
- Adhesive (syringe)
The strain sensor and attaching harness cannot be repaired and must be replaced if found to be defective.
The strain sensor is bonded with adhesive and bolted to mounting blocks on the main frame at the left side near the back of the cab.
To ensure correct functioning of a replacement strain sensor it is ESSENTIAL that the following replacement procedure is used.
When a replacement sensor is installed the frame temperature must be no lower than +15°C. Local heating must NOT be applied to the frame to achieve this temperature.
1. Disconnect the strain sensor harness from the control unit harness and remove the strain sensor.
2. Thoroughly clean the mounting blocks on the machine frame and ensure that ALL traces of adhesive are removed.
3. Dry the faces of the mounting blocks and using a straight edge and feeler gauges, check that the faces are aligned within 0.05 mm (.002 in). If necessary carefully file the blocks to this tolerance and clean out the bolt holes, using a thread tap if required.
4. Remove the transit link and protective tape from the replacement sensor and clean the mounting faces, DO NOT SCRAPE. The mounting faces are on the FLAT side of the sensor.
5. Ensure that the faces of the mounting blocks are clean and dry and apply a thin film of Loctite 330 Adhesive (p/n 154-8874).
6. Ensure that the faces of the sensor are clean and dry and apply a coating of Loctite 737 Activator.
7. Install the sensor on the mounting blocks and tighten the bolts evenly to a torque setting of 35 N·m (25 lb ft). Connect the sensor harness to the control unit harness and secure as required.
Strain sensor installation
8. Allow the adhesive to cure for at least two hours at an ambient temperature of +15°C. The machine may be moved during this time and the boom slowly raised and lowered, but the attachment should not be loaded.
9. Before the system is calibrated, a cycle of strain loading must be applied to the machine to aid settlement of the sensor bond. With the boom retracted, raise a load which is within the capability of the machine to approximately 45°. Lower the load and return the control quickly to the hold position just before the attachment reaches the ground so that the main frame is loaded when the boom stops. Repeat this at least ten times.
10. If the sensor was replaced on a 'Type 1' system, calibrate the system. Refer to the topic 'Field Calibration - Type 1 System'.
11. If the sensor was replaced on a 'Type 2' system, calibrate the system. Refer to the topic 'Field Calibration - Type 2 System'.
Field Calibration - Type 1 System
Equipment Required
- 6V7070 Digital Multimeter or equivalent.
- 4C4029 Trimmer adjustment tool for potentiometers. Re-calibration will be necessary following the replacement of a strain sensor or control unit. All measurements and adjustments are made at the control unit located in the side of the operators seat base.
- The tire pressure, and tire ballast where required, must be correct.
- The engine should be operated at low idle throughout the procedure.
- The operator must remain in the machine, and no other person should climb onto the machine during the procedure.
- 4C4029 Trimmer adjustment tool for potentiometers. Re-calibration will be necessary following the replacement of a strain sensor or control unit. All measurements and adjustments are made at the control unit located in the side of the operators seat base.
Control Unit
Some stages of the calibration procedure require operation of the duty switch to illuminate the 'stabilizers lowered' indicator. These stages apply whether or not the machine is equipped with stabilizers.
Procedure:
The attachment carriage and forks must be installed.
1. Position the machine on level ground.
2. Fully retract the boom and position the forks 150 mm (6 in) above the ground with no load.
3. Remove the covers from the side of the seat base and the control unit. Refer to the table on the inside of the control unit cover for the voltage values required in Steps 8, 10, 13 and 15.
4. Set the duty range switch on the display to 'Stabilizers Raised' (stabilizers raised indicator illuminated).
5. Connect a digital voltmeter between test points TP10 (-) and TP3 (+).
6. Adjust zero preset Z to obtain a reading of zero volts, 0.010 volts.
7. Connect the voltmeter between terminals TP10 (-) and TP17 (+).
8. Adjust preset P3 to obtain the reading shown against P3 on the control unit cover.
9. Fully extend the boom and position the attachment coupler 150 mm (6 in) above the ground.
10. Adjust preset P2 to obtain the reading shown against P2 on the control unit cover.
11. Fully retract the boom and position the attachment coupler 150 mm (6 in) above the ground.
12. Set the duty range switch to stabilizers lowered (stabilizers lowered indicator illuminated - but if equipped with stabilizers these must remain RAISED).
13. Adjust preset P6 to obtain the reading shown against P6 on the control unit cover.
14. Fully extend the boom and position the attachment coupler 150 mm (6 in) above the ground.
15. Adjust preset P5 to obtain the reading shown against P5 on the control unit cover.
16. Check the system for correct operation.
Field Calibration - Type 2 System
Equipment Required
- Personal Computer (PC)
- 386SX or above with a 3.5 drive and serial port operating DOS 3.1 or above.
- 137-9745 Test Group which comprises:
- 386SX or above with a 3.5 drive and serial port operating DOS 3.1 or above.
The longitudinal stability indicator (LSI) is calibrated initially using test weights before the machine is shipped from the factory. The Type 2 LSI systems installed on TH62, TH63, TH82 and TH83 machines are calibrated in four positions, and on TH103 machines in six positions.
In the initial calibration, a six digit number is originated for each of the calibration positions. The numbers are entered into the LSI software which is contained in the system control unit located in the operators seat base. These calibration number sets are unique to the machine being calibrated, and are recorded on a decal attached to the inside of the control unit cover.
If re-calibration is required, for example following the replacement of a control unit, the recorded number sets on the original control unit cover are entered into the new control unit using a 137-9745 Test Group and a suitable PC.
The field calibration software is contained on the 137-9748 Set Up Program Disk and will guide a technician through the calibration. This instruction provides a guide to the whole procedure and must be used in conjunction with the test group software.
1. Position the machine on level ground and remove the attachment carriage, or attachment from the attachment coupler.
2. Fully retract the boom and position the bottom of the attachment coupler 150 mm (6 in) above the ground.
3. Stop the engine.
Control unit location 3LN1-749, 4TM1-1234, 3NN1-783, 5WM1-1587, 3KN1-438, 3JN1-578, 3RN1-1071, 3PN1-529
Control unit location 3LN750-Up, 4TM1235-Up, 3NN784-Up, 5WM1588-Up, 3KN439-Up, 3JN579-Up, 3RN1072-Up, 3PN530-Up
4. Remove the LSI control unit cover.
Control unit
5. Ensure that switch (2) is in the UP position.
6. Install the 136-6458 Cable or 145-5809 Cable between the PC and connector (1) in the control unit.
7. Switch the PC on. Wait until fully loaded.
8. Install the 137-9748 program disk in the PC.
9. Turn the engine start switch key to the ON position. If using 'Windows' continue with Step 10. If using DOS continue from Step 12.
10. Move the screen cursor over the 'MAIN' icon and double click.
11. Move the screen cursor over the 'MSDOS' prompt icon and double click.
12. Key in a: and press the enter key (note - type a, followed by a FULL colon).
13. Key in th and press the enter key.
14. Using the arrow keys move the screen cursor to 'Field Calib'.
15. Press the enter key. The screen will now show the calibration default settings. These may vary from those shown on the control unit cover.
16. Move the cursor to the 'Zero' position and press the enter key
17. The screen will now display the instruction 'Move boom to zero position' - the machine is already in this position (Step 2).
18. Move the cursor to the 'Zero' position and press the enter key. The audible alarm should now sound twice, confirming that the zero position has been entered and areas 1 to 4, or 1 to 6 on TH103 machines, will default to the factory settings of 000100.
NOTE: If a replacement control unit has been installed, a new six digit zero reference number will have appeared in the top and middle screen boxes. Copy this number into the new control unit cover.
19. Move the screen cursor to 'Calibrate area 1' and press the enter key.
20. Refer to the inside of the original control unit cover and key in the value shown for area 1 (six digit number must be entered - not including + or - signs). Press the enter key.
21. Check on the screen that the value entered is the same as that shown on the control unit cover.
22. Move the screen cursor to 'Calibrate area 2' and press the enter key.
23. Refer to the inside of the original control unit cover and key in the value shown for area 2 (six digit number must be entered - not including + or - signs). Press the enter key.
24. Check on the screen that the value entered is the same as that shown on the control unit cover.
25. Move the screen cursor to 'Calibrate area 3' and press the enter key.
26. Refer to the inside of the original control unit cover and key in the value shown for area 3 (six digit number must be entered - not including + or - signs). Press the enter key.
27. Check on the screen that the value entered is the same as that shown on the control unit cover.
28. Move the screen cursor to 'Calibrate area 4' and press the enter key.
29. Refer to the inside of the original control unit cover and key in the value shown for area 4 (six digit number must be entered - not including + or - signs). Press the enter key.
30. Check on the screen that the value entered is the same as that shown on the control unit cover.
STEPS 31 to 36 APPLY TO TH103 MACHINES ONLY
31. Move the screen cursor to 'Calibrate area 5' and press the enter key.
32. Refer to the inside of the original control unit cover and key in the value shown for area 5 (six digit number must be entered - not including + or - signs). Press the enter key.
33. Check on the screen that the value entered is the same as that shown on the control unit cover.
34. Move the screen cursor to 'Calibrate area 6'and press the enter key.
35. Refer to the inside of the original control unit cover and key in the value shown for area 6 (six digit number must be entered - not including + or - signs). Press the enter key.
36. Check on the screen that the value entered is the same as that shown on the control unit cover.
37. Move the screen cursor to 'Boom weight' and press the enter key.
38. Refer to the inside of the control unit cover and key in the value shown for Boom Reference. Press the enter key.
39. Move the cursor to 'Exit' and press the enter key. The screen will now revert to the first screen shown after switching on, with the cursor on exit. Press the enter key to leave the program.
40. Switch the PC off and remove the 145-5809 Cable.
41. If a new control unit is installed, copy the numbers for boom weight and areas 1 to 4, from the original cover into the cover of the new unit. If TH103 machine, copy the numbers for boom weight and areas 1 to 6 from the original cover into the cover of the new unit.
42. Check the system for correct operation.