Cat TH255 Telehandler Supplemental service Manual (en 15000) - PDF DOWNLOAD

Super Compact - TH255 EN15000 Supplemental Service Manual February 2012

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EN15000 – Affected Serial Number Range • TH255  S/N TBS00627 & After

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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’s moment sensing system. The intention of the new regulation is to prevent longitudinal (forward) instability from occurring by reducing the machine’s 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.

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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 foresees that the cutout can be overridden temporarily and also that it is deactivated when the machine is dynamic (park brake not applied AND shifter in forward or reverse).

• Summary: – machine requires electronic control of both the static and dynamic moments associated with load movement in the longitudinal machine axis

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EN15000 – System is NOT: • Replacement for load chart • Substitute for operator training • Protection from lateral instability risks • Protection from backward instability risks

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EN15000 – Components • LSI Sensor (PRE – EN15000) CAT P/N:320-9307

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• LSI Sensor (EN15000) CAT P/N:382-8745

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EN15000 – Components • Boom Position Switches

Switch Connector Conn Pos

Wire Designation

Color / Gauge

1

Power Supply

Brown / #22 AWG

2

Gnd

Blue / #22 AWG

3

Load

Black / #22 AWG

Specs: - PNP, Current Sourcing - Normally Open - 10-30VDC, 200mA Load Max. - 5mm Sensing Range

• Standard on all CE compliant TH255 machines produced after August 31th 2010.

– Redundant Installation (2x same sensor) – Boom extension detection, less or more then 1m detection – Signal of switches determines the boom lift down speed

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EN15000 – Components • LSI CAN System – 2 identical modules (Ground Module & I/O Module) – CAN communication between Ground Module, I/O Module and the LSI Display – 2x 120Ω resistors • 1 in the Cab Harness of the LSI Display, close to the display • 1 in the Frame Option Harness, close to the ground module

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EN15000 – Components • Two identical modules – Same software – Upload via analyzer port (same cable as current TH to be used for upload) – Ground Module: inputs and output function signals – I/O Module: Receive hardwired signals and transmit CAN messages

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EN15000 – Components • New lift cylinder design with flow control valve integrated – Power supply to valve via Ground Module – Power supply determines Lift Down Speed 1.

2.

3.

• 1. Check Valve – allows free flow out of the rod side of the lift cylinder • 2. Flow Control - two symbols integrated into one cartridge and work together to give the desired flow • 3. Counterbalance – general load holding valve 10

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EN15000 – Components • LSI Display (PRE- EN15000) CAT P/N:312-3331

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• LSI Display (EN15000) CAT P/N:377-9838

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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%

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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 LED’s will flash simultaneously and an intermittent audible alarm will sound.

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• LSI Display – Red LED on; the rear axle unloaded percentage trip point (100% rated capacity) has been met or exceeded. All LED’s will flash simultaneously and a continuous audible alarm will sound. All aggravating movements are cut out.

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EN15000 – Functionality Modes • Active Mode – 2 different active modes • Less then 1 meter extended – ACTIVE ZONE 1 (detected by boom sensors) • More then 1 meter extended – ACTIVE ZONE 2 (detected by boom sensors)

– LSI Display visual and audible indicating the rear axle unladen percentage – Lockout of hydraulic functions, except Tele In and Lift Up for CE-market – Override possible via override switch (max. 30sec, creep speed) – Shifter in Neutral or Park Brake applied

• Passive Mode – LSI Display visual and audible indicating the rear axle unladen percentage – NO hydraulic functions are locked out – Shifter in Forward or Reverse AND Park Brake NOT applied 14

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EN15000 – Active Mode

LED Off

At (1), the rear axle is unloaded to 50% and the current delivered decreases.

At (2), the rear axle is unloaded to 75% and the current delivered decreases.

At (3), the axle becomes completely unloaded and all hydraulic functions are locked out except lift up and tele in, so lift down current drops to zero.

At (4), the LSI Override Switch is activated and Creep current is delivered (30seconds max).

Reset point after overload: <75% for min. 2 seconds 15

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EN15000 – Active Mode If the rear axle unladen percentage meets or exceeds the 100% by pulse or continuous, the LED’s on the LSI Display start flashing including an continuous beep and the aggravating movements will be cut out.

The aggravating movement will re-engage when the rear axle unladen percentage is lower than 75% for minimum 2 seconds.

The LSI Display LED’s stop flashing when this is achieved.

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EN15000 – Passive Mode

LED On

- Regardless the rear axle unladen percentage, the lift down current stays constant.

- No hydraulic lock out, only visual and audible alarm.

- Passive Mode Indicator illuminates when the shifter is in forward or reverse AND the park brake is NOT applied.

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EN15000 – Passive Mode TH255 AND

=

EN15000 PASSIVE

AND

=

EN15000 PASSIVE

=

EN15000 ACTIVE

F

R AND /

N

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. No speed reduction of boom lift down 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 below the LSI display is illuminated.

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EN15000 – Settings TH255

Active Zone 1 (Boom Extended < 1m)

Active Zone 2 (Boom Extended > 1m) Creep Mode Passive Mode (EN15000 mode disabled)

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Rear Axle Load (OMD %)

mA Output [mA]

Lift Down Time (sec)

< 50

1220

7.5-9

 50 OMD < 75

1040

10-13

75

850

12-15

< 50

850

12-15

50 OMD < 75

800

15-18

 75

740

16-19

100 (until < 75)

560

22-25

< 50

1500

6

 50 OMD < 75

1500

6

 75

1500

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EN15000 – Electrical Overview

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EN15000 – Sensor Testing

B

A C

To check both cells of the LSI Sensor, connector SN161 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

SN161

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.

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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 GD158 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 GD158.

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.

GD158

Ensure the machine is on level ground, tires straight and the boom down, fully retracted and without load when you take the measurements.

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EN15000 – Error Code 8514

• 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.

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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 70-80 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.

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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 70-80 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.

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EN15000 – Error Code 8518

• 8518 -> LSI CUTOUT OUTPUT – SHORT TO BATTERY OR OPEN CIRCUIT • LSI System’s 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 Remote Input Module J1-5. 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. 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.

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EN15000 – Error Code 8519 • 8519 -> LSI OUT OF CALIBRATION • The LSI-CAN Check Points have not been calibrated or failed a check with the Ground Module.

• The Ground Module 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 Ground Module were to be replaced in the field, the Ground Module logged LSI-CAN check points will need to be re-entered in the CALIBRATIONS menu. Once this has been completed, the LSICAN check point test in the OPERATOR TOOLS menu will need to be performed.

• The LSI System does not need to be calibrated. The Ground Module just needs the information from the LSI System so the Ground Module can perform the a system integrity check.

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EN15000 – Error Code 99151

• 99151 -> FUNCTIONS LOCKED OUT – LSI SOFTWARE VERSION IMPROPER • The Ground Module has determined the LSI Display is not an acceptable software version.

• Replace the LSI Display and perform the field calibration procedure.

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EN15000 – Error Code 99152

• 99152 -> LSI FAULTY – SYSTEM FLASH CRC ERROR • The LSI System has an internal error.

• Replace the LSI Display and perform the field calibration procedure

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EN15000 – Error Code 99153

• 99153 -> LSI FAULTY – DATA FLASH CRC ERROR • The LSI System has an internal error.

• Replace the LSI Display and perform the field calibration procedure

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EN15000 – Error Code 99154

• 99154 => 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 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 70-80 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.

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Help Message

DTC

Trigger / Possible Symptom(s)

Actions

Latch / Reset Condition

CHECK

System OK

001

Ground Module detects no problems exist

-

-

N/A

Power Cycle

211

Power was cylced ON

-

-

N/A

Lift Down Valve Short to Battery

335

The desired current is 0mA and the digital output driver's diagnostic feedback is low for a period of 250ms

Deactivate Lift Down Output

Latched

Frame Option Harness

Lift Down Valve Open Circuit

336

Actual lift down current < LIFTDNOC(PWM) for a period of 250ms

Deactivate Lift Down Output

Latched

Frame Option Harness

Deactivate all Module Outputs

Not Latched - Revert to normal operation when battery voltage greater than or equal to 11V for at least 1000ms.

Frame Option Harness, Enclosed Cab Harness, Base Frame Harness

Battery Voltage Low System Shutdown

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Battery voltage is less than 11V for at least 5000ms

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Help Message

DTC

Trigger / Possible Symptom(s)

Actions

Latch / Reset Condition

CHECK

Battery Voltage to High – System Shutdown

442

Battery voltage is greater than 16V for at least 250ms

Deactivate all Module Outputs

Latched - Fix supply voltage

Frame Option Harness, Enclosed Cab Harness, Base Frame Harness

462

Machine configured to CE Market and (J1-5 = HIGH) and (Passive_Mode2 = TRUE) for 3 seconds or more

Default machine to Active Mode

Latched

Machine Configuration, Enclosed Cab Harness, Frame Option Harness

998

Ground Module has detected an anomaly in EEPROM. Verify all settings using the analyzer.

Deactivate all Module Outputs – Reset the section of EEPROM where the failure occurred to defaults.

Latched – Possibly replace Board

Verify all settings, Possibly replace Ground Module or Remote Input Module

2336

LSI Override Switch depressed at Startup or for longer than 40 Seconds

Default machine to LSI Cutout (if not in passive mode and not in LSI calibration mode) and disregard LSI Override Switch input override.

Latched

Restart Machine and/or Check LSI Override Switch

4578

Ground Module has detected that the pressure sensor voltage Is less than 0.25V or greater than 4.75V

Limit all lift down speed to Creep Mode without activating LSI Cutout

Latched

Pressure Switch and/or Frame Option Harness

Conflicting Drive Direction Signals

EEPROM Failure – Check All Settings

Load Moment Shutoff Input - Invalid Signal

Lift Valve – Pressure Sensor Voltage Out of Range

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DTC

Trigger / Possible Symptom(s)

Actions

Latch / Reset Condition

CHECK

6638

Ground Module lost CAN bus communication with LSI Display and no messages have been received for a period of 1 Second

Default machine to LSI Cutout (if not in passive mode) with operation only available via LSI Override Switch (Creep Mode Operation)

Not Latched - Revert to normal operation when CAN bus communication is re-established

CAN Resistance, LSI Display and/or Frame Option Harness, Enclosed Cab Harness, Cab Roof Harness

6642

Ground Module lost Can bus communication with Remote Input Module and no messages have been received for a period of 1 second

Default machine to LSI Cutout (if not in passive mode or not in LSI calibration mode) with operation only available via LSI Override Switch (Creep Mode operation)

Not Latched - Revert to normal operation when CAN bus communication is re-established

CAN Resistance, Remote Input Module and/or Frame Option Harness, Enclosed Cab Harness, Cab Roof Harness

9949

Ground Module has detected an anomaly in EEPROM with regard to the Machine Setup configuration

Deactivate all Module Outputs

Latched - until EEPROM data in associated area is changed

Machine Setup Configuration and/or Ground Module

Telescope Out Valve – Short to Battery

33123

Desired current is 0mA and the digital output driver's diagnostic feedback is low for a period of 250ms

Deactivate Telescope Out Output. Also deactivate Telescope Enable if machine is in LSI Cutout

Latched

Frame Option Harness

Lift Enable Valve – Short to Ground

33159

(ST_LINE_TRANS_LEN>10), evaluate every 80ms

Deactivate Lift Enable Output

Latched

Frame Option Harness

Help Message

CAN Bus Failure - LSI

Can Bus Failure – Remote Input Module

Machine Configuration Out of Range - Check All Settings

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Help Message

DTC

Trigger / Possible Symptom(s)

Actions

Latch / Reset Condition

CHECK

Lift Enable Valve – Open Circuit

33160

Valve is commanded ON, diagnostic feedback is low for 1 second and no STG detected

Deactivate Lift Enable Output

Latched

Frame Option Harness

Lift Enable Valve – Short to Battery

33161

Valve is commanded OFF and the diagnostic feedback is low

Deactivate Lift Enable Output

Latched

Frame Option Harness

Telescope Out Valve – Open Circuit

33186

Actual Telescope Out current < (TOUTOC) for a period of 250ms

Deactivate Telescope Out Output

Latched

Frame Option Harness

Telescope Out Valve – Short to Ground

33188

Actual Telescope Out current > (TOUTSTG) for a period of 250ms

Deactivate Telescope Out Output

Latched

Frame Option Harness

Lift Down Valve – Short to Ground

33407

Actual lift down current > LIFTDNSTG(PWM) for a period of 250ms

Deactivate Lift Down Output

Latched

Frame Option Harness

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Help Message

DTC

Trigger / Possible Symptom(s)

Actions

Latch / Reset Condition

CHECK

Function Enable Output - Short to Battery

33438

Valve is commanded OFF and the diagnostic feedback is low

Deactivate Function Enable

Latched

Frame Option Harness, Enclosed Cab Harness, Base Frame Harness

Telescope Enable Valve - Open Circuit

33439

Valve is commanded ON, diagnostic feedback is low for 1 second and no STG detected

Deactivate Telescope Enable Output

Latched

Frame Option Harness

Telescope Enable Valve - Short to Battery

33440

Valve is commanded OFF and the diagnostic feedback is low

Deactivate Telescope Enable Output

Latched

Frame Option Harness

33441

(ST_LINE_TRANS_PMI>10), evaluate every 80ms and machine is configured for CE Market

Deactivate Indicator Output

Latched

Frame Option Harness, Enclosed Cab Harness, Cab Roof Harness

33442

Indicator is commanded OFF and the diagnostic feedback is low and machine is configured for CE Market

Deactivate Indicator Output

Latched

Frame Option Harness, Enclosed Cab Harness, Cab Roof Harness

Passive Mode Indicator - Short to Ground

Passive Mode Indicator - Short to Battery

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Help Message

DTC

Trigger / Possible Symptom(s)

Actions

Latch / Reset Condition

CHECK

Function Enable Output - Short to Ground

33443

(ST_LINE_TRANS_FEN>10), evaluate every 80ms

Deactivate Function Enable

Latched

Frame Option Harnes, Enclosed Cab Harness, Base Frame Harness

Telescope Enable Valve - Short to Ground

33444

(ST_LINE_TRANS_TEN>10), evaluate every 80ms

Deactivate Telescope Enable Output

Latched

Frame Option Harness

99161

Ground Module has detected that Remote Input Module Software is not compatible (Major version does not match)

Deactivate All Module Outputs

Latched

Reflash and/or possibly replace Remote Input Module

Functions Locked Out - Remote Input Module Software Version Improper

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EN15000 – Field Calibration Procedure

Go to Section 9.13 of Service Manual 31200364 Rev. B (or later)

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