SERVICE LETTER

Reference: CAT 1507

st th
Revised Date: December 21 , 2015 (Original Publication Date: December 17 , 2015)

PRODUCT SUPPORT PROGRAM FOR REPLACING LSI

PRIORITY DISPLAY AND SENSOR ON CERTAIN CATERPILLAR
TELEHANDLERS COMPLIANT WITH EN15000 NORM
REVISION: Revised to include reimbursable labor time.

ATTENTION: This program must be administered as soon as possible. When reporting the repair, use “CAT
1507” as the Part number and “7451” as the group Number, 56 as the Warranty Claim
Description Code and “T” as the SIMS Description Code.
Exception: If the repair is done after failure, use “CAT 1507” as the Part number and “7451” as
the group Number, 96 as the Warranty Claim Description Code and “Z” as the SIMS
Description Code.
NOTE: The information supplied in this service letter may not be valid after the termination date of this
program. Do not perform the work outlined in this Service Letter after the termination date
without contacting first your Caterpillar Product Analyst.

PROGRAM TERMINATION DATE:

December 17th, 2016

DESCRIPTION OF ISSUE:
The updated display and sensor are the solution for the LSI related failures reported on certain Caterpillar
Telehandlers. The updated display provides solutions for “Loss of calibration” faults and faults triggered by the
LSI system during the engine cranking process. The updated sensor has an improved temperature
compensation factor, reducing the LSI system from being out of calibration during fluctuations in temperature.
APPLICABLE PRODUCTS:
This issue affects certain CAT Telehandlers.

Model Affected Serial Numbers

TH336C (HRC) (MJR) not applicable
TH337C (HRC) (DJB) not applicable
TH337C (LRC) (SXJ) not applicable
TH406C (HRC) (GAT) not applicable
TH407C (LRC) RCH00150, 151, 152
TH407C (HRC) (MLH) not applicable
TH407C (LRC) (JJT) not applicable
TH414C (HRC) (KEK) not applicable
TH414C (LRC) (RWW) not applicable.
TH514C (HRC) (MWC) not applicable
TH417C (HRC) RRJ00173
TH417C (LRC) (RRW) not applicable

Page 1 of 11
PARTS NEEDED:
The following part must be ordered to accomplish this update:

Part Number Description Quantity

484-9763 Display, LSI 1
452-7079 Sensor, LSI 1
454-3968 Bolt, Hex M10X40 2
Kit, Loctite® F246 (A2460) + Initiator No. 1(may also be
Dealer Sourced 1
denoted as No. 5)
Dealer Sourced Loctite® 7063 degreasing agent 1
Dealer Sourced Sealant, Soudal® Silirub 2 (Black) 1

ACTION REQUIRED:
*** Dealer Parts Stock***
Remove all 377-9838(P1.06), 448-8663(P1.07) LSI Displays and 382-8745 LSI Sensors from dealer stock.

*** Affected Product ***

Replace the components as per group 1 or 2 depending on your serial prefix, using the procedures detailed on
the next pages. A claim may be submitted under this Service Letter number for parts, labor and travel and
mileage.
IMPORTANT: Ensure that the unit is upgraded with the most recent UGM Software versions for an
optimized performance of the LSI system. The latest software is available from the telehandler website.

SERVICE CLAIM ALLOWANCES:

*** Dealer Parts Stock ***
Submit one (1) claim – using special product identification number ‘99Z00159’ – for all 377-9838, 448-8663 LSI
Displays and 382-8745 LSI Sensor.
*** Affected Product ***
To receive reimbursement, file a service claim through the normal CAT service claims process. When filing this
claim through the CAT system, please use the following codes in the appropriate input fields:

Input Field Before Failure After Failure

Part Causing Failure CAT1507 CAT1507
Group Number 7451 7451
Warranty Claim Description 56 96
SIMS Description Code T z

The reimbursement terms of this program are as follows:

JLG Dealer Suggested Customer Suggested
Parts % Labor Hrs % Parts % Labor Hrs % Parts % Labor Hrs %
100% 100% 0% 0% 0% 0%
Labor Time: This is a 2.5-hour job.
Travel is up to 3.0 Hours.

Page 2 of 11
Removing Sensor and Cleaning Mounting residual degreasing agent that remains on the
Surface mounting surface or bolt holes.

Position machine on a firm and level surface, where it 7. Inspect the bottom of the LSI sensor to ensure
can remain stationary for at least two (2) hours. Ensure cleanliness equal to that of the mounting surface.
the frame is level using the level in the cab. Ensure 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.

LSI Sensor
Figure 2 Clean, flat axle surface.
IMPORTANT! FOR THE LSI SYSTEM TO
FUNCTION PROPERLY, IT IS NECESSARY THAT
SN213 THE SURFACE ON THE AXLE IS PERFECTLY
Connect CLEAN, FLAT, WITHOUT IRREGULARITY,
PROTRUSIONS, OR DIFFERENCES OF LEVEL.

Sensor installation
CAUTION: USE ALL APPLICABLE SAFETY
PRECAUTIONS WHILE WORKING ON,
UNDER OR AROUND ANY MACHINERY.
Figure 1. Sensor and connector Location.

2. Refer to figure 1. Locate and unplug (SN213) the

existing Load Stability Indicator (LSI) sensor from the
cable coming from the Rear Frame Harness, located
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. Figure 3. Initiator on Sensor Pads
4. Use a cleaner tool to remove any adhesive 1. Refer to figure 3. Sparingly apply Initiator No. 1 (may
and or rust. also be denoted as Initiator No. 5) to each of the
5. Ensure the threads in the axle for the sensor’s sensor’s metallic mounting pads. as shown above.
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, etc. 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
Figure 4. Adhesive on Sensor Surface.

Page 3 of 11
2. Refer to Figure 4. Apply a 1/8th inch (3mm) bead of
non-expired Loctite adhesive A2460 (F246) to each
axle surface area, around each of the mounting holes.
IMPORTANT: No substitutions or replacements for
Loctite F246(A2460) are allowed. Only Loctite
F246(A2460) is to be used.

Figure 7. Torque process

Figure 5. Use spatula to evenly distribute the adhesive
3. Refer to figure 5. Use a spatula to even distribute the
adhesive over each axle surface area. Use the
following sequence to minimize the amount of
adhesive entering into the threaded holes.
a. Position the spatula over the center of the
threaded hole.
b. Move the spatula for the center of the hole to the
left. Remove the excessive adhesive on the
spatula.
c. Position the spatula over the center of the
threaded hole.
d. Move the spatula for the center of the hole to the
Right. Remove the excessive adhesive on the
spatula.
e. Repeat step A through D for the other
remaining hole.
Figure 6. Sensor installed “finger tight”.
4. Refer to figure 6.Install the sensor (P/N 452-7079)
onto the mounting surface of the axle. Ensure the
electrical lead exits the sensor in the corner direction,
similar to the original sensor.
5. Refer to figure 7. Insert the two retention bolts (P/N
454-3968) and tighten in the following sequence:
a. Tighten each bolt “finger tight.”
b. Tighten each bolt to a torque setting of 30 Nm +5/-
0 (22 ft-lb).
c. Tighten each bolt to a torque setting of 70 Nm
+10/-0(59 ft-lb).
6. Scribe a permanent mark from bolt head onto sensor.
Figure 8. Sealant
7. Refer to figure 8. Apply a the black silicone sealant
around the sensor.
a. Start- Position the nozzle underneath the
harness lead, apply a large bead around the
sensor.
b. Ensure that you end with your nozzle over the
starting point.
8. Make a clean finish, using a spatula and soap water.
9. STOP!
IMPORTANT! IT I S IMPERATIVE THE AXLE
AND SENSOR ARE NOT STRESSED DURING
THE BONDING TIME. DO NOT DRIVE THE
MACHINE FOR ONE (1) HOUR AFTER
INSTALLING THE SENSOR.
10. After a minimum 1 hour of stationary cure time, the
machine may be driven.
8. 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.

Page 4 of 11
Display Replacement 3. Refer to figure 9. Confirm if the new display received
is with the latest software P1.09 and install the new
1. Locate the Load Stability Indicator’ display inside the
LSI display (P/N 462-3221).
cabin.
4. Continuo and Perform the calibration procedure as
2. Unscrew and disconnect the existing display
described on the next following pages.

Figure 9 LSI Display P1.09

Calibration Procedures
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, 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, depending on model. This is
considered the LSI Field calibration. No scales are required for accomplishment of this 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, 10 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 3. Refer to figure 10 .Fully retract the boom and if
calibration procedure. equipped, lower the outriggers. Shut the machine
OFF.
2. Remove the standard carriage and weight assembly.

Approx. 3 sec.

Figure 10 Fully Retract, outriggers fully down. Figure 11. Press-Hold ‘SYSTEM CHECK’ until ‘LED5 Orange’ stops
illuminating and buzzer sounds.

Page 5 of 11
4. Refer to figure 11. With ignition key in OFF position, 6. Refer to figure 13 & 14. The first green LED then
press and hold SYSTEM CHECK button on LSI illuminates. With no attachment, outriggers down (if
display and turn ignition key to engine START equipped) and boom fully retracted, lift boom to
position. Release the ignition key when engine start is maximum boom angle.
achieved, but continue to hold SYSTEM CHECK
button on LSI display until the orange LED on LSI
display goes out and buzzer sounds. Release
SYSTEM CHECK button.

Figure 15. Press SYSTEM CHECK .

7. Refer to figure 15. Press the SYSTEM CHECK button

on the LSI display and release. The first 3 green
Figure 12. Press ‘SYSTEM CHECK’ when only ‘LED3 Green’ LEDs will illuminate. The third then second green
illuminates. LEDs will go out as the calibration point is recorded.
5. Refer to figure 12. 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.

Figure 16. Buzzer sounds and ‘LED 6 Red’ will illuminate

8. Refer to figure 16. The first green LED goes out and
buzzer sounds then the red LED illuminates.

Figure 13. ‘LED 1 Green’ Illuminated.

Weight

s
Figure 17. Lower boom, fully raise outriggers and Pick up weight.

9. Refer to figure 17. 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.

Model Weight on Rear Axle

TH336C 500 kg (1102 lb)

TH337C, TH406C, TH407C 600 kg (1323 lb)
TH414C, TH514C, TH417C 1000 kg (2205 lb)
Table 1
Figure 14 Lift Boom to MAX Boom Angle.

Page 6 of 11
 SLOWLY EXTEND!

Weight

Figure 18. Slowly extend until rear axle weight is achieved.

10. Refer to figure 18 & table 1. Slowly extend the boom

until the rear axle weight as per table 1 is achieved.
Figure 19. Press ‘SYSTEM CHECK’, Buzzer sounds and ALL LED’s
are flashing.
11. Refer to figure 19. 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 on page 12 to
finalize the calibration.

Page 7 of 11
B. Field Calibration
To calibrate the LSI, certain conditions must be met:
• The sensor must be installed according to the procedure on pages 5 & 6.
• 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, 10 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 & 2.
Distance 'X'
Test
Model Market
Weight Xplace
Xtip (1) Xcal (2)
(3)

3000 kg 1228 mm 918 mm

TH336C CE na
(6614 lb) (48 in) (36 in)
3000 kg 1484 mm 1082 mm
TH337C CE na
(6614 lb) (58 in) (43 in)

3000 kg 1879 mm 1476 mm

CE na
(6614 lb) (74 in) (58 in)
TH406C
3000 kg 1879 mm 1476 mm
AUS na
(6614 lb) (74 in) (58 in)

3000 kg 1968 mm 1586 mm

CE na
(6614 lb) (77 in) (62 in)
TH407C
3000 kg 1968 mm 1586 mm
AUS na
(6614 lb) (77 in) (62 in) Figure 21. Xtip (1). (For reference only)

CE
1000 kg 2509 mm 1916 mm 1500 mm 2. Refer to figure 21. By confirming that the machine tips
(2205 lb) (99 in) (75 in) (59 in)
TH414C at this point, the correct amount of weight is now on
AUS
1000 kg 2837 mm 2259 mm 1500 mm the forks.
(2205 lb) (112 in) (89 in) (59 in)

1000 kg 3139 mm 2592 mm 1500 mm

3. The machine control system must be powered on for
CE
(2205 lb) (124 in) (102 in) (59 in) at least 3 minutes before calibration.
TH514C
2100 kg 1942 mm 1545 mm 1500 mm
AUS
(4630 lb) (76 in) (61 in) (59 in)

1000 kg 2050 mm 1713 mm 1500 mm

CE
(2205 lb) (81 in) (67 in) (59 in)
TH417C
1000 kg 2050 mm 1713 mm 1500 mm
AUS Est.
(2205 lb) (81 in) (67 in) (59 in)
Weight
Table 2

Figure 22. Boom Retracted

SLOWLY EXTEND!
4. Refer to figure 22. The machine must be on a level
Est.
surface with the wheels steered straight, boom
Weight retracted horizontal and park brake OFF with
standard carriage, forks and test weight attached to
the machine.
Figure 20. Slowly extend till tipping point.

1. Refer to figure 20. With the estimated test weight on

the forks, start the machine and extend the boom
horizontally until the machine starts to tip. Pressing
Est.
the LSI override button may be required to reach Weight
tipping point.
2m (6.5 ft)
Figure 23. Drive forward 2m (6.5 ft) minimum

5. Refer to figure 23. 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.

Page 8 of 11
NOTE: IF UNITS IS EQIUPPED WITH OUTRIGGERS
PLEASE COMPLETE NEXT STEP, OTHERWISE SKIP
TO STEP 8:
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 buzzer sounds. Release
SYSTEM CHECK button.

Xplace
Est.
Weight

Figure 27. Press ‘SYSTEM CHECK’ when only ‘LED3 Green’

Figure 24. Apply Parking Brake. Detach carriage and weight at illuminates.
Xplace (For reference only)
2. Refer to figure 27. The LEDs will perform a sequence.
7. Refer to figure 24 and table 2. Detach standard When only the third green LED illuminates, press the
carriage including forks and test weight at a minimum SYSTEM CHECK button.
distance of Xplace (3) in front of the machine.
Pressing the LSI override button may be required.

Figure 28. ‘LED 1 Green’ Illuminated.

Figure 25 Fully Retract, outriggers fully down.

8. Refer to figure 25. 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.

Approx. 3 sec.

Figure 26. Press-Hold ‘SYSTEM CHECK’ until ‘LED5 Orange’ stops Figure 29. Lift Boom to MAX Boom Angle.
illuminating and buzzer sounds.
3. Refer to figure 28 & 29. The first green LED then
1. Refer to figure 26. With ignition key in OFF position,
illuminates. With no attachment and boom retracted,
press and hold SYSTEM CHECK button on LSI
lift boom fully.

Page 9 of 11
 Figure 30. Press SYSTEM CHECK .
4. Refer to figure 30. 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.
Figure 31. Buzzer sounds and ‘LED 6 Red’ will illuminate.
5. Refer to figure 31. The first green LED goes out and
buzzer sounds then the red LED illuminates.
Weight
s point is recorded, buzzer sounds and the LEDs will
Figure 32. Lower boom, fully raise outriggers and Pick up weight.
6. Refer to figure 32. 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.
Page 10 of 11
SLOWLY EXTEND OR RETRACT!
Weight
Figure 33. slowly extend or retract the boom to the distance of
Xcal (2). For reference only.
7. Refer to figure 33. 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.
Figure 34. Press ‘SYSTEM CHECK’, Buzzer sounds and ALL LED’s
are flashing.
8. Refer to figure 34. Press the SYSTEM CHECK button
on the LSI display and release. As the calibration
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
With the LSI calibrated, the UGM also needs calibrated
and verified.
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:
a. “Remove Weights and Attachments”, telescope in
and press “OK”.
b. TH414(C), TH514(C) and TH417(C) ONLY: “Fully
deploy stabilizers”, press “OK”. Pressing the LSI
Override button may be required
c. “TELESCOPE IN and FULLY LIFT UP”, press
“OK”.
d. “STOP, WAIT ONE MINUTE”, wait at least one
minute and press “OK”.
e. “PRESS ENTER TO SET CHECK POINT”, press
“OK”
f. Screen defaults back to “CALIBRATIONS:
LSI_CAN CHECK POINT”.
g. Press “C” for approximate two seconds to return to
normal display screen.
11. LSI Can Check is now complete.
12. Return machine to service.

Page 11 of 11