JLG

Telehandlers_EN15000
– Service Training

LATEST UPDATE : 07-03-2011

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 EN15000 – The new European norm
Where the requirements originate from?
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.
What is the intent of this new regulation ?
The intent of the new regulation is to improve longitudinal (forward)
instability from occurring. JLG Telehandlers equipped with EN15000
systems achieve this by controlling and limiting the machine function
speeds (BOOM LIFT DOWN) for loading/unloading functions when the
machine is stationary and before 100% axle unloaded cutout point is
reached. These new regulations are part of the European Norm
EN15000:2008.
Effectiveness?
All telehandlers produced after August 31st 2010 shall comply with the
requirements of EN15000:2008.

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 EN15000 – Requirements
„ Requirements:
– EN15000 compliant system requires electronic control of both the static and
dynamic moments associated with load movement in the longitudinal 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

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 EN15000_What are the main changes ?
1. A new type of LSI sensor ( redundant signal type sensor) is installed on the rear axle in the
same area where the previous sensor was installed.
2. A new LSI display is installed on the cab post structure in the cab, in the same place where the
previous one was.
3. Relevant electrical harnesses are modified to accommodate the two abovementioned
components.
4. A new Ground Module Software designed to deal with EN15000 requirements is installed in the
UGM. 4170094 Ver.P3.6 for Bradford; 1001102953 Ver.P1.1 for Xenon.
5. On 5,6,7,8 & 9 mt machines, a Boom retracted sensor is installed to detect fully retracted
position of the telescopic boom.This input is used to turn the LSI system into PASSIVE mode.
6. A PASSIVE MODE LIGHT is introduced on 5,6,7,8 & 9 mt machines to inform the operator
when the LSI system is in PASSIVE mode.
At the same time we also need to be aware of:
7. A new sensor installation procedure.
8. A new LSI calibration procedure.
9. Requirement for a periodical LSI Check to be performed as standard maintenance every 500
working hours.
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 EN15000 – Components comparison

„ LSI Display (NON- EN15000) „ LSI Display (EN15000)

„ P/N 1001127308

LSI – CAN MODULE SOFTWARE P1.03 for all models.

NOTE:At the moment the software can be updated only by
the supplier.

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 EN15000 – Components comparison
„ LSI Sensor (NON – EN15000) „ LSI Sensor (EN15000)

The previous sensor

provides a single signal This new sensor provides
(one sensor only)The a redundant signal ( two
sensor is connected sensors in one). The
with two wires. sensor is connected
through three wires.

Sensor P/N 1001129371 for 13 mt.models

All LSI sensors prior to EN15000.
Sensor P/N 1001129370 for all other models

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SET UP for 6,7,8,&9 mt. machines_Main components

LSI sensor on rear axle LSI Instrument with

LSI PASSIVE
mode light.
Light illuminates to
indicate Passive
Protection.
Detail of LSI display in cab

IMPORTANT : LSI is in ACTIVE mode only with the FNR selector in NEUTRAL and the
PARK BRAKE is ON and when the Boom is NOT RETRACTED.
In Passive mode, the automatic function cutout and/or slow down feature is disabled.
Visual indication of longitudinal stability limits are still illuminated.
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SET UP for 6,7,8,&9 mt. machines_Boom retracted sensor
The boom retracted sensor
detects the boom when it is in the
fully retracted position.
This input is used to set LSI in
Passive mode when boom is fully
retracted.

6 & 7 mt. Machines

8 & 9 mt. Machines

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SET UP for 6,7,8,&9 mt. machines_LSI PASSIVE MODE light

Light ON Light OFF

Boom fully retracted ( LSI in PASSIVE mode) Boom extended ( LSI in ACTIVE mode)

Light ON

Boom extended + FWD/REV drive selected + PARK BRAKE OFF( LSI in PASSIVE mode)
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SET UP for 13 & 17 mt. machines_Main components

LSI sensor on rear axle LSI Instrument

IMPORTANT : for the above mentioned models, LSI is

always in ACTIVE mode
Detail of LSI display in cab

NOTE: If the machine is equipped with a boom retracted sensor, this will have no influence on the LSI
system. In other words, the LSI system stays always in ACTIVE mode.

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 EN15000 – Electrical Overview (valid for all
models)

REFERENCE ELECTRIC
SCHEMATICS.
For 8,9,13 & 17 mt
models see
Dwg.1870200 Rev. N
For 6 & 7 mt models see
Dwg.1001100375 Rev.K

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 EN15000 – Display operation
„ LSI Display „ LSI Display
– Ignition switch ON, instrument “ON” – Machine lifting a load, axle unloaded
status, small green LED in the moment between 50 – 89.9%
“System Check” button.
• 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 „ 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 exceeded.
90-99.9%. If the amber LED comes All LED’s will blink in combination with
on, the LED’s start flashing in a continuous audible alarm.
combination with an intermittent
audible alarm.

TELE OUT, BOOM DOWN and TILT functions are DISABLED !

(for Australian version, BOOM UP is disabled too).

The operator can press and hold

override pushbutton to temporarily
( 30 sec.)enable cutout functions
while he operates the joystick.
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EN15000 – DISPLAY LOAD MOMENT VALUE
Where can the LOAD MOMENT VALUE be read in the ANALYZER /DIAGNOSTIC menu ?

Push C + OK for 2 seconds

to enter Analyzer menu „ Rear Axle Unloaded Moment Percentage

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 EN15000 – System Functionality

„ Theoretical:
– If the main lift down function is selected the control system will initially enforce
a maximum lift down current defined by the parameter LSI Slow Speed once
the commanded Lift Down current equals the LSI Slow Speed parameter. If
the LSI display is reporting the rear axle is unloaded by 70% or more within
the predetermined LSI evaluation time, the control system will reduce the
maximum allowable lift down current to LSI Creep Speed parameter.
Otherwise at the end of the initial period after each new input to the joystick,
the control system will permit a new maximum lift down current defined by the
LSI High Speed parameter. Finally, if the LSI display reports the rear axle is
unloaded by 70% or more after the predetermined LSI evaluation time, the
control system will reduce the maximum allowable lift down current back down
to the LSI Slow Speed parameter.
– If the cabin joystick and its rollers are returned to their neutral positions and
the lift down function is re-engaged with the boom not retracted, the control
system repeats the above mentioned steps until the boom is retracted or the
LSI system inhibits the motion.

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 EN15000 – System Functionality
„ Theoretical:
– If the LSI display reports the rear axle has reached 100% unloaded
point and the machine is configured as CE, all hydraulic functions will
be inhibited with the exception of the lift up, telescope in, and the
hydraulic quick switch. The inhibited functions will not be permitted to
operate unless the LSI shutoff button on the cabin keypad is
depressed (30 second window of operation) or the UGM determines
the rear axle has sufficient load on it.
– If the machine is configured as AUSTRALIA, the control system will
respond in the same manner as indicated above except lift up
function will also be inhibited.

NOTE: Even if the UGM determines hydraulic function motion is

safe again, it will not permit operation of the inhibited functions until
the joystick and its rollers are returned to their neutral positions for the
system reset period.

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 EN15000 – What is the EN15000 system not?

„ Replacement for load chart

„ Substitute for operator training

„ Load chart validation tool

„ Protection from lateral instability risks

„ Protection from backward instability risks

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 Examples of
operation

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 EN15000 – Settings Explanation
The following terms and definition apply when the LSI system is in ACTIVE mode only.

„ LSI High Speed Current: Max. mA setting for boom down movement.
„ LSI Low Speed Current: Max. mA setting for boom down movement when axle load percentage
exceeds 70% after evaluation period.
„ LSI Creep Speed Current: Max. mA setting for boom down movement when axle load percentage
exceeds 70% during evaluation period
„ 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
„ 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.
„ Reset Point Percentage: Rear axle load percentage point to reset overload condition
„ Reset Point Debounce Time: Time that joystick must be in neutral position after Reset Point
is passed to get max. allowed speed back (LOW or Creep
Speed) in stabile condition.
„ LMI-CAN Trip Point Percentage of Load: Trigger point for mA output (LOW or Creep).
„ LSI Low Speed Current (TELE): Max. mA setting for TELE OUT movement when axle load percentage
exceeds 70% after evaluation period
„ 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
„ 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.

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 BOOM DOWN – Neutral – Boom fully retracted (only certain
models)
In machines equipped with Boom retracted switch ( 5-6-7-8 &9 m models) LSI system in PASSIVE mode
when one of the two following conditions is satisfied:
- the boom is fully retracted
- FWD or REV drive is selected.

Rear Axle
Load (%)

100
85
70

Output Time
Current(mA)
High Speed (EN15000 Passive)
1600

0
Time

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 BOOM DOWN– Neutral – Boom extended
LSI system in ACTIVE mode; there is an initial evaluation time, followed by a ramp up time. In this
case the load and the speed of boom descent are safe, therefore the system allows full speed for the
boom down function.

Rear Axle
Load (%)
100
85
70

Time

Output
Current(mA)
LSI High Speed (EN15000 Active)
1310

1110
LSI Low Speed (EN15000 Active)

0 Time
20ms 120ms
Ramp Up Time
NOTE: FIGURES AND GRAPHS ARE JUST AS REFERENCE!
Eval. Time

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 BOOM DOWN - Neutral – Boom further extended

LSI system in ACTIVE mode. The boom is extended a bit ( example = 0,5 m). The load moment during
BOOM DOWN command is increased as a consequence of the peak of signal from the sensor and
detected during the evaluation time phase, therefore,, the system slows the function down.

100
85
70

Time

Output
Current(mA)
LSI High Speed (EN15000 Active)
1310

1110
LSI Low Speed (EN15000 Active) LSI Low Speed (EN15000 Active)

0 Time
20ms 120ms
Ramp Up Time
NOTE: FIGURES AND GRAPHS JUST AS REFERENCE!
Eval. Time

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 BOOM DOWN – Neutral – Boom further extended

LSI system in ACTIVE mode. The boom is extended further. As a consequence of the increased
signal from the sensor, the system initially slows the function down and then locks the movement to
prevent instability (Function CUT OUT).

100
85
70

Time

Output
Current(mA)
LSI High Speed (EN15000 Active)
1310

1110
LSI Low Speed (EN15000 Active) LSI Low Speed (EN15000 Active)

Boom Down Movement Locked Out

0
20ms 120ms Time
Ramp Up Time
NOTE: FIGURES AND GRAPHS JUST AS REFERENCE!
Eval. Time

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 EN15000 – Rear Axle Evaluation Time
Rear Axle Eval. Time occurs in ACTIVE mode only, after each initial joystick movement greater than LSI Low Speed
Output Current -
Joystick Deflection

1310mA

1110mA
1048mA

Ramp Up Time
Rear Axle Evaluation Time
100%

80%

Scenario 1 Scenario 2

Time

Example:
LSI High Speed Current = 1310mA
LSI Low Speed Current = 1110mA
0% Joystick Deflection = 0mA Output Demand
100% Joystick Deflection = 1310mA Demand
< 85% Joystick Deflection = No evaluation Time
(1310mA x 84% = 1100.4mA)

NOTE: FIGURES AND GRAPHS ARE JUST AS REFERENCE!

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 EN15000 – LSI Creep Speed Current
LSI Creep Speed Current is the max. output current in case the rear axle load percentage is greater or exceeds 70%
during the rear axle evaluation time.
Rear Axle
Load (%)

100
85
70

Output Time
Current(mA)
High - 1310

Low - 1110
Creep - 950

Scenario 1 Scenario 2

0 Time
20ms 0 20ms

Eval. Time Eval. Time

Example:
LSI Low Speed Current = 1110mA
LSI Creep Speed Current = 950mA
NOTE: FIGURES AND GRAPHS ARE JUST AS REFERENCE!
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„ Overload Condition
EN15000 –
– All lights are blinking, continuous alarm
– Hydraulic functions are locked out, except boom raise,
Overload
boom retract and hydraulic QC (Australia = boom raise also
locked out).

„ Re-engage lift / extend functionality

Requirements: an “x” percentage of the rear axle load and a neutralization of
the joystick for “x” seconds.
– Raise or retract the boom, rear axle load reset points after overload
• Rear Axle Load 90% => 5,6,7,8,& 9 mt
• Rear Axle Load 85% => 13 & 17 mt
– LED’s stop blinking after return to safe condition
– Joystick must be in neutral position after return to safe condition for “x”
seconds which is called the Reset Point Debounce Time.
• Reset Point Debounce Time 1 second => 5,6,7,8,& 9 mt
• Reset Point Debounce Time 1.5 second => 13 & 17 mt

„ LSI Override
– 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

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Installation and
calibration

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EN15000- LSI sensor removal & installation

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 EN15000_ Calibration procedure_Step 1
CONDITIONS
• The sensor must be mounted according to installation instructions
• The vehicle control system must be powered on for at least 10 min before calibration to allow the sensor
to stabilize
• The calibration procedure shall be conducted with the weights as necessary; the driver shall be in the
cab.
• If the vehicle is equipped with stabilizers they must be fully lowered to the end stroke of the cylinders, no
attachment should be connected to the machine.
• The vehicle shall be on a level surface with the wheels steered straight and park brake OFF, with
straight driving over a distance of at least two meters being the last movement before entering a
calibration point.
• Lift and lower the boom stopping suddenly to induce bounce on the back axle 10 times before
calibration. You will need to use the LSI Override button on the keypad.
• The calibration must be completed within 30 minutes after starting procedure.
• Position the rear wheels of the machine centrally on the weight scales.

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 EN15000_ Calibration procedure_Step 2

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 EN15000_ Calibration procedure_Step 3

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 EN15000_ Calibration procedure_Step 4

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 EN15000_ Calibration procedure_Step 5

Note: Value indicated in pict. is for reference only

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 EN15000_ Calibration procedure_Step 6

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EN15000_ Calibration procedure_UGM Calibration
After the LSI is calibrated, also the UGM needs to be properly set

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 EN15000_ Calibration procedure_UGM Calibration check
After the LSI calibration is completed, it is possible and opportune to perform a calibration check.

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 EN15000 – Field Calibration Procedure

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EN15000 – Sensor Testing
Counter Connector: DT06-3S

1) Create a 3 pin measuring cable, use a Deutsch

counter connector (DT06-3S), pins (303-4970)
JLG P/N 4460539 Harness side connector
JLG P/N 4460536 Instrument side connector

2) Plug the counter connector in the LSI Sensor (SN213)

3) Connect multimeter to pin A, to measure sensor 1

Connect multimeter to pin C, to measure sensor 2

4) If the current (DC) is in the range of 50mA +/- 10mA on a

flat surface, the sensor is working.
CONNECTOR X81
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 EN15000 – Sensor and Harness Testing
Counter Connector: DT06-08SA

+12V

Sensor 1

Sensor 2
1) Create a 8 pin measuring cable, use a Deutsch
counter connector pins (303-4969).
JLG P/N 4460931 Instrument side connector
JLG P/N 4460930 Harness side connector

2) Plug the counter connector in the cab floor harness (GD84)

after the LSI-Display is disconnected.

3) Connect multimeter to pin 4, to measure sensor 1

Connect multimeter to pin 5, to measure sensor 2

4) If the current (DC) is in the range of 50mA +/- 10mA on a flat

GD84 surface, the sensor is working and the harness from sensor to
display is ok.

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Troubleshooting
and related fault
codes
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 EN15000 – Error Code 99154
„ 99154 => LSI FAULTY – LOAD CELLS A AND B
DISAGREEMENT
„ 5% sensing current difference between load cells.
„ The LSI System is reporting it is seeing a 5% 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 and confirm the proper LSI Sensor was
installed. If none of the above work, before taking further
action, contact the Engineering Product Support. If no further
directions are provided, then use a torque wrench and verify the
LSI Sensor is still secured to the axle at 70 N-m. If the bolt
turns at all, then the machine must undergo the field calibration.
If the torque setting is correct, as a last step, replace the LSI
Sensor and perform a field calibration.

41 An Oshkosh Corporation Company

 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 see 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 located in the proper
connector position, check the crimps of the respective wire in
the LSI display. Next, visually inspect the sensor for damage
and confirm the proper LSI Sensor was installed.
„ If no further directions are provided, then use a torque wrench
and verify the LSI Sensor is still secured to the axle at 70 N-m.
If the bolt turns at all, then the machine must undergo the field
calibration. If the torque setting is correct, as a last step,
replace the LSI Sensor and perform a field calibration.

43 An Oshkosh Corporation Company

 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 see 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 located in the proper
connector position, check the crimps of the respective wire in
the LSI display. Next, visually inspect the sensor for damage
and confirm the proper LSI Sensor was installed.
„ If no further directions are provided, then use a torque wrench
and verify the LSI Sensor is still secured to the axle at 70 N-m.
If the bolt turns at all, then the machine must undergo the field
calibration. If the torque setting is correct, as a last step,
replace the LSI Sensor and perform a field calibration.

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 EN15000 – Error Code 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 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
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.
If everything check out, then most likely there has been internal
damage to LSI Display and it should be replaced; which will
unfortunately drive the need for a field calibration.

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 EN15000 – Error Code 99151

„ 99151 -> 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.

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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 8515

„ 8515 -> LSI DETECTED BUT NOT CONFIGURED

„ The UGM has detected the LSI System is connected but
not 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 correct the configuration selection under
the MACHINE SETUP menu.

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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 UGM.
„ The UGM 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 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 be
performed.
„ The LSI System does not need calibrated. The UGM just
needs the information from the LSI System so the UGM can
perform the a system integrity check.

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 Maintenance

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 EN15000 - Maintenance ACCESS LEVEL 2 Pwd =
33271

OPERATOR TOOLS

Every 500 working hours, it is prescribed to perform a LSI-

CAN SYTEM CHECK according to the procedure:

With this procedure, the system checks the values of load

cell 1 and load cell 2, and compare them to the values stored
in memory during the system calibration. If the values are
within X number range, the system gives a PASS, if the
values are out of range, the system gives a FAIL.

MUST RECEIVE A “PASS” AT THE END

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 Frequently
asked
questions

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 EN15000 Ground Module Software
In line with JLG standard practice, software is available On Line Express.
EN15000 functionality is supported only by software versions starting from:

4170094 Ver.P3.6 for 8,9,13 & 17 mt models;

1001102953 Ver.P1.1 for 6 & 7 mt models

If the same software is uploaded onto a telehandler prior to the EN15000, the MACHINE SET UP menu
offers the possibility to select the correct type of LSI:
The remaining selections are
for:
LSI : Std telehandler prior to
EN15000
LMI: Telehandler equipped with
the LMIS ( 3B6 system) for
suspended loads ( OPTION)
LSI-CAN+LMI: EN15000
Telehandler equipped with
LMIS ( 3B6 system) for
suspended loads ( OPTION).
NOTE: LSI –CAN is the DEFAULT selection ( valid for EN15000 telehandlers).
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