Op-Serv-Pts 3124288 07-26

Operation & Safety,
Service & Maintenance, &
Illustrated Parts Manual Supplement
JLG
LOAD
SENSING
SYSTEM
Scissors Lift Products
P/N
3124288
July 26, 2013
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
A
GENERAL
C
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate.
MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component
parts.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• NEVER WORK UNDER AN ELEVATED SIZZOR UNTIL
PLATFORM HAS BEEN SAFELY RESTRAINED FROM
ANY MOVEMENT BY BLOCKING OR OVERHEAD
SLING, OR BOOM SAFETY PROP HAS BEEN
ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/
OPERATOR.
• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.
B
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high, potentially dangerous pressures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of
the system.
3124288
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
– JLG Lift –
A-1
INTRODUCTION
REVISION LOG
Original Issue
Revised
Revised
Revised
Revised
Revised
Revised
Revised
Revised
Revised
Revised
Revised
Revised
Revised
A-2
-
June 13, 2003
July 28, 2003
August 11, 2003
September 12, 2003
March 1, 2004
October 15, 2004
July 15, 2006
October 26, 2007
June 4, 2010
March 31, 2011
March 1, 2012
August 11, 2012
January 30, 2013
July 26, 2013
– JLG Lift –
3124288
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH
PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A
B
C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - ANALYZER OPERATION - ALL
1.1
1.2
1.3
1.4
Introduction & Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Viewing & Adjusting Parameters Using the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . .1-3
SECTION 2 - OPERATION - (LE, MRT, RTS)
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Connecting the JLG Control System Analyzer (LE, MRT & RTS). . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Help Menu & Fault Codes (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Diagnostic Menu (LE, MRT & RTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Personalities (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Machine Setup Menu (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Calibration Menu (LE, MRT & RTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
JLG Workstation in the Sky™ Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
SECTION 3 - OPERATION - (ES, RT)
3.1
3.2
3.3
3.4
3.5
3.6
Connecting the JLG Control System Analyzer (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Help Menu & Fault Codes (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Diagnostic Menu (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Personalities (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Machine Setup Menu (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Calibration Menu (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
SECTION 4 - OPERATION - (RS)
4.1
4.2
4.3
4.4
4.5
4.6
Connecting the JLG Control System Analyzer (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Help Menu & Fault Codes (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Diagnostic Menu (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Personalities MENU (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Calibration Menu (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Angle Sensor Calibration (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Load Sensing System Calibration (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
5.1
5.2
5.3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
SECTION 6 - SERVICE - (RS)
6.1
6.2
6.3
6.4
6.5
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Description (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Calibration (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Angle Sensor Calibration Procedure (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Platform Load Sensing System Calibration Procedure (RS) . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Testing and Evaluation (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
LSS Troubleshooting (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
LSS Component Removal/Installation (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Pressure Transducer Removal (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Pressure Transducer Installation (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
– JLG Lift –
i
TABLE OF CONTENTS (Continued)
10RS Angle Sensor Removal (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
10RS Angle Sensor Installation (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6RS Angle Sensor Removal (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6RS Angle Sensor Installation (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
LSS Connector Pin Assignments (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
SECTION 7 - PARTS
7-1
7-2
7-3
7-4
7-5
Load Sensing System Installation (260MRT, M3369/M4069 & 3369LE/4069LE) . . . . . . . . . . . . .7-2
Load Sensing System Installation (500RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Load Sensing System Installation (1930ES/2032ES/2630ES/ 2646ES/3246ES) . . . . . . . . . . . . .7-8
Load Sensing System Installation (6RS/10RS/1932RS/3248RS). . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Load Sensing System Installation (3394RT/4394RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
LIST OF FIGURES
FIGURE NO.
2-1.
3-1.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
6-1.
6-2.
6-3.
6-4.
TITLE
PAGE NO.
Module Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Module Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Load Sense Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
260MRT Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
M3369/M4069 & 3369LE/4069LE Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
500RTS Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
ES Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
RT Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
LSS Pressure Transducers Location - 1932RS/6RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
LSS Pressure Transducers Location - 3248RS/10RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
LSS - Scissor Arm Angle Sensor - (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
LSS - Electrical Component Schematic - (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
LIST OF TABLES
TABLE NO.
2-1
2-2
2-3
2-4
2-5
2-6
3-1
3-2
3-3
3-4
3-5
4-1
4-2
4-3
4-4
4-5
5-1
5-2
ii
TITLE
PAGE NO.
LSS Fault Codes (LE, MRT and RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Diagnostic Menu Descriptions (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Personalities Menu Description (LE, MRT, RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Machine Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
LSS Module Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
LSS Fault Codes (LE, MRT and RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Diagnostic Menu Descriptions (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Personalities (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
LSS Fault Codes (RS ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Diagnostic Menu Descriptions (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Personalities Menu Description (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Angle Sensor Calibration Failure Troubleshooting (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Load Calibration Failure Troubleshooting (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
LSS Troubleshooting Chart - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
LSS Troubleshooting Chart - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
– JLG Lift –
3124288
TABLE OF CONTENTS
5-3
5-4
5-5
5-6
5-7
6-1
6-2
6-3
6-4
6-5
6-6
6-7
3124288
LSS Troubleshooting Chart - Measurement Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
LSS Troubleshooting Chart - Host System Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
LSS Module System Interface Connector - Power & Digital (J1 - Grey) . . . . . . . . . . . . . . . . . . . .5-10
LSS Module System Interface Connector – Communication (J1 - Black) . . . . . . . . . . . . . . . . . . .5-10
LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Platform Calibration Weight - RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
System Activation Height - RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
LSS Troubleshooting - RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Connections to Host Control System (J1-Black) (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Connections to Host Control System (J2-Blue) (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Angle Sensor Connector Pinout (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Pressure Transducer Connector Pinout (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
– JLG Lift –
iii
TABLE OF CONTENTS (Continued)
NOTES:
iv
– JLG Lift –
3124288
SECTION 1 - ANALYZER OPERATION - ALL
SECTION 1. ANALYZER OPERATION - ALL
NOTE: This manual is intended as a supplement to the individual machine’s Operators and Safety Manual.
1.1
INTRODUCTION & OPERATION
1.2
USING THE ANALYZER
With the machine power on and the analyzer connected
properly, the analyzer will display the following:
NOTE: It is the responsibility of the owner/user/operator/lessor/lessee to read & understand this manual and the
machine Operators & Safety Manual and to prevent
overloading the platform. Do not operate a machine
with a disconnected or inoperative Load Sensing
System.
The JLG-designed Load Sensing System (LSS) measures
platform load. If the actual platform load exceeds the
selected Rated Load, the following will occur:
1. The Overload Visual Warning Indicator will flash at
the selected control position (platform or ground).
2. The Platform and Ground Alarms will sound 5 seconds On, and 2 seconds Off.
3. All normal movement will be prevented from the
platform control position (optional - ground control
functions may be prevented).
4. Further movement is permitted by:
a. Removing the excess platform load until actual
platform load is less than Rated Load.
b. By an authorized person at the ground control
position (optional - ground control functions
may be prevented).
THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE
OR MORE OF THE FOLLOWING CONDITIONS OCCUR:
a. LSS System initial installation
b. LSS Module replacement
c. LSS Sensor removal or replacement
d. Addition or removal of certain platform mounted
accessories. (Refer to Calibration in Section 2)
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
If you press ENTER at the HELP: PRESS ENTER display
and there are no faults, the Analyzer will display EVERYTHING OK. In the event of a fault, the Analyzer will display
a Help Message.
e. Platform is removed, replaced, repaired or
shows evidence of impact.
If ENTER is pressed again, the Analyzer will display
LOGGED HELP, a record of the last 16 faults. Use the left
and right arrow keys to scroll through the fault log. To
return to the top level menu, press the ESC key twice.
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION
VERIFICATION NOT TO EXCEED 6 MONTHS FROM PREVIOUS
VERIFICATION. REFER TO TESTING & EVALUATION IN SECTION
2.
When a top level menu entry is selected, a new set of
menu items will be displayed.
Calibration of the Load Sensing System is performed by
connecting the JLG Analyzer (Analyzer Kit, JLG part no.
2901443). All calibration procedures are menu driven
through the use of the Analyzer.
3124288
Pressing ENTER while viewing any of the above menu
entries will display additional sub-menus. Typically, the
sub-menu is where parameter information is displayed or
changed. You may only view Personality settings while in
Access Level 2. Access Level 1 is required to change Personality settings and calibrate.
– JLG Lift –
1-1
SECTION 1 - ANALYZER OPERATION - ALL
The ESC key may be used to leave a sub-menu at any
time.
1.3
Once the correct password is displayed, press ENTER.
The access level should display the following, if the password was entered correctly:
CHANGING THE ACCESS LEVEL OF THE
HAND HELD ANALYZER
When the analyzer is first connected, you will be in access
level 2 which enables you to only view most settings
which cannot be changed until you enter a password to
advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level,
the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu. For example:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings.
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
Continue using the arrow keys until all the remaining digits
of the password is shown.
1-2
– JLG Lift –
3124288
SECTION 1 - ANALYZER OPERATION - ALL
1.4
VIEWING & ADJUSTING PARAMETERS
USING THE HAND HELD ANALYZER
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
PERSONALITIES:
DRIVE ACCEL 3.0s
PERSONALITIES:
OVR DEBNCE 3.0s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular personality. If the value does not change when pressing the
up and down arrows, check the access level to ensure
you are at Access Level 1.
3124288
– JLG Lift –
1-3
SECTION 1 - ANALYZER OPERATION - ALL
NOTES:
1-4
– JLG Lift –
3124288
SECTION 2 - OPERATION - (LE, MRT, RTS)
SECTION 2. OPERATION - (LE, MRT, RTS)
2.1
CONNECTING THE JLG CONTROL
SYSTEM ANALYZER (LE, MRT & RTS)
2.2
THE LOAD SENSING SYSTEM MODULE HAS AN INDEPENDENT
ANALYZER CONNECTION LOCATED NEAR THE MODULE. DO
NOT CONFUSE IT WITH THE ANALYZER CONNECTION FROM
THE HOST CONTROL SYSTEM.
1. Connect the cable supplied with the Analyzer to the
LSS Module located beneath the platform and connect the remaining end of the cable to the analyzer.
NOTE: The cable has a four-pin connector at each end of
the cable; The cable cannot be connected backwards.
2. Power-up the Control System by turning the key to
the Platform or Ground position and pulling both
emergency stop buttons.
HELP MENU & FAULT CODES (LE, MRT
& RTS)
The Help Menu is a troubleshooting tool to communicate
detected System Faults to the technician. The following
table documents the Faults for the Load Sensing System.
To access the Help Menu, use the LEFT and RIGHT arrow
keys to select HELP: PRESS ENTER from the Top Level
Menu. Press the ENTER key to view the menu.
When accessing the Help Menu, the JLG Analyzer will display EVERYTHING OK if the platform is not overloaded
and no difficulties are detected. Otherwise, the JLG Analyzer will display OVERLOADED.
In the event of difficulty, the user can press ENTER again
to display Logged Help, which is a record of the last 16
Fault Messages. The following table lists each Help/
Logged Message, the Flash Code (for each Fault, the
module will flash the two-digit code on its LED) triggered
by the Fault, and a Description of the Situation (cause).
Table 2-1. LSS Fault Codes (LE, MRT and RTS)
Help/Logged
Message
Everything OK
Flash
Code
Description of Situation
LED ON The "Normal" Help Message
<MIN CAL
Calibration attempt Unsuccessful, Empty Platform appears to weigh too little. Improper Model Selection (Machine
Setup) may cause the LSS Module to expect the wrong Empty Platform Weight. This also may be caused by a damaged
sensor or associated wiring. Finally, this condition may occur if mechanical interference between the platform and support structure exists (all weight must transfer through sensors).
>MAX CAL
Calibration attempt Unsuccessful, Empty Platform appears to weigh too much. This situation has the same root causes
as the "<MIN CAL" Fault Message.
BATT TOO LOW
4/1
Incoming Supply Voltage <9.0 Vdc. The control system’s battery voltage is too low due to excessive electrical load or
discharge.
BATT TOO HIGH
4/4
Incoming Supply Voltage >34.0 Vdc. The control system’s battery voltage is too high. This may be due to over-charging or improper charger operation.
CELL #1 ERROR
8/1
Cell #1’s Bridge <2V, >3V, or could not read Cell #1’s Internal Memory. This situation indicates damage to the sensor
or its wiring.
CELL #2 ERROR
8/2
Cell #2’s Bridge <2V, >3V, or could not read Cell #2’s Internal Memory. This situation indicates damage to the sensor
or its wiring.
CELL #3 ERROR
8/3
Cell #3’s Bridge <2V, >3V, or could not read Cell #3’s Internal Memory. This situation indicates damage to the sensor
or its wiring.
CELL #4 ERROR
8/4
Cell #4’s Bridge <2V, >3V, or could not read Cell #4’s Internal Memory. This situation indicates damage to the sensor
or its wiring.
WATCHDOG RST
9/1
Microprocessor’s Watchdog Timer Triggered. This is an indication that the LSS Module has been exposed to excessive
electrical noise, or has experienced a hardware difficulty.
EEPROM ERROR
9/2
Memory used to retain Personality/Machine Setup/Calibration has been corrupted and must be reset by verifying all
entries and re-calibrating.
NO CAL
9/3
Calibration has not been successfully completed. A new LSS Module will display this message until properly calibrated.
3124288
– JLG Lift –
2-1
SECTION 2 - OPERATION - (LE, MRT, RTS)
Table 2-1. LSS Fault Codes (LE, MRT and RTS)
Help/Logged
Message
INTERNAL ERR
Flash
Code
9/9
Description of Situation
Pin excitation <4.25 V. The sensors may be excessively loading the excitation supply, or the LSS Module may have
hardware difficulty.
High Side Driver Error. The load attached to OUT1 or OUT2 is shorted to battery or ground and has been detected by the
LSS module.
DRDY Interrupt from A/D missing. This may indicate an LSS Module hardware difficulty.
2-2
– JLG Lift –
3124288
SECTION 2 - OPERATION - (LE, MRT, RTS)
2.3
DIAGNOSTIC MENU (LE, MRT & RTS)
To access the Diagnostic Menu, use the LEFT and RIGHT
Arrow keys to select DIAGNOSTICS from the Top Level
Menu. Press the ENTER key to view the menu.
The Diagnostic Load Menu is another troubleshooting tool
for the Load Sensing System. Sensor and status information is presented in real-time for the technician. Several
sub-menus exist to organize the data.
Note that the Diagnostic Menu changes based on MODEL
Parameter in the Machine Setup Menu (some displays are
suppressed). The information presented in the following
table will be proper when MODEL=3369LE/4069LE/
500RTS or 260MRT (refer to Machine Setup Menu).
Press the LEFT and RIGHT Arrow keys to view the displays and select the various sub-menus (PIN 1, PIN 2,
etc.). To access a sub-menu, press the ENTER key. Once
in a sub-menu, press the LEFT and RIGHT Arrow keys to
view the various displays (just like a Top Level menu). To
exit a sub-menu, press the ESC key.
The table below details the structure of the Diagnostic
Menu, and describes the meaning of each piece of information presented.
Table 2-2. Diagnostic Menu Descriptions (LE, MRT & RTS)
Diagnostics Menu
(Displayed on Analyzer 1st Line)
Parameter (Displayed
on Analyzer 2nd Line)
Parameter Value
(Displayed on Analyzer 2nd
Line)
Description
PLTLOAD
+XXXX LBS or Kg
Displays (Total Measured Force – Empty Platform
Calibration)
PLTGROS
+XXXX LBS or Kg
Displays Total Measured Force (Sum of Pins 1 thru 4
LOAD)
OVERLOADED?
Yes / No
Displays Current LSS Module Overload Status
CELL 1:
LOAD
+XXXX LBS or Kg
Displays Calibrated Cell Reading in Current Units
RDG
+XX.XXXX mV/V
Displays Pin Reading in mV/V
INPUT
+XX.XXXX mV
GAIN
XXXX.X
LOAD
+XXXX LBS or Kg
Displays Calibrated Cell Reading in Current Units
RDG
+XX.XXXX mV/V
Displays Pin Reading in mV/V
Displays Pin Reading in mV
Displays calibration factor from pin
CELL 2:
Displays Pin Reading in mV
INPUT
+XX.XXXX mV
GAIN
XXXX.X
LOAD
+XXXX LBS or Kg
Displays Calibrated Cell Reading in Current Units
RDG
+XX.XXXX mV/V
Displays Pin Reading in mV/V
Displays calibration factor from pin
CELL 3:
INPUT
+XX.XXXX mV
GAIN
XXXX.X
LOAD
+XXXX LBS or Kg
Displays Calibrated Cell Reading in Current Units
RDG
+XX.XXXX mV/V
Displays Pin Reading in mV/V
Displays Pin Reading in mV
Displays calibration factor from pin
CELL 4:
INPUT
+XX.XXXX mV
GAIN
XXXX.X
Displays calibration factor from pin
OVLOAD STAT
OFF / ON
State of Overload Status Digital Output
Displays Pin Reading in mV
SYSTEM:
3124288
WARNING
OFF / ON
State of Warning Digital Output
MOT INHIBIT
NO / YES
Status of Internal Motion Inhibit Flag
MOTION #1
OFF / ON
Status of Digital Input #1
– JLG Lift –
2-3
SECTION 2 - OPERATION - (LE, MRT, RTS)
Table 2-2. Diagnostic Menu Descriptions (LE, MRT & RTS)
Diagnostics Menu
(Displayed on Analyzer 1st Line)
Parameter (Displayed
on Analyzer 2nd Line)
Parameter Value
(Displayed on Analyzer 2nd
Line)
Description
MOTION #2
OFF / ON
Status of Digital Input #2
MOTION #3*
OFF / ON
Status of Digital Input #3
BATTERY
XX.XXV
Displays Current Battery Voltage
EXCITE
X.XXXXV
Displays Load Pin Excitation Voltage
TEMP
+/-XXX.X Deg C
Display the Temperature Sensed by the LSS Module
for Scissor Pin Compensation
VERSIONS:
SOFTWARE
PX.XX
Displays LSS Module Software Version
HARDWARE
X
Display LSS Module Hardware Revision
ANALYZER
2-4
VX.XXXX
– JLG Lift –
Displays Analyzer Software Version
3124288
SECTION 2 - OPERATION - (LE, MRT, RTS)
2.4
PERSONALITIES (LE, MRT & RTS)
NOTE: The following parameter adjust performance of the
Load Sensing System. All adjustments must be made
at access level 1 (33271).
THE SETTINGS UNDER THE FACTORY MENU OPTION ARE
UNIQUE TO EACH MODULE. THESE SETTINGS ARE NOT TO BE
ALTERED. IN THE EVENT THAT THESE SETTINGS ARE
ALTERED, CONTACT JLG WITH THE SERIAL NUMBER OF THE
MODULE.
Table 2-3. Personalities Menu Description (LE, MRT, RTS)
Personalities
(Displayed on
Analyzer 1st line)
Parameter (Displayed
On Analyzer 2nd line)
Description
4069LE
3369LE
500RTS
260MRT
No
Extensions2628 LBS
(1192 KGS)
OVERLD XXXX
LBS (KGS)
ACC’Y XXXX LBS
(KGS)
MTN DELAY XS
OVR DBNCE XS
OVR HOLD XS
FACTORY
3124288
#1 GAIN
X.XXXX
#1 ZERO
+X.XXXX mV
#2 GAIN
X.XXXX
#2 ZERO
+X.XXXX mV
#3 GAIN
X.XXXX
#3ZERO
+X.XXXX mV
#4 GAIN
X.XXXX
#4 ZERO
+X.XXXX mV
EX GAIN
X.XXXX
TEMP OFFS
+/- XXX.X
Displays/adjusts the overload limit for this
AWP
Displays/adjusts a de-rating for
Accessories
Displays/adjusts the delay between motion
ceasing and evaluation of overload
Displays/adjusts the de-bounce delay
before an overload
Displays/adjusts the minimum delay
before an overload can be released.
Displays/calibrates the LSS Module analog
channel gain
Displays/calibrates the LSS Module analog
channel offset.
Displays/calibrates the LSS Module analog
channel gain
Displays/calibrates the LSS Module analog
channel offset
Displays/calibrates the LSS Module analog
channel gain
Displays/calibrates the LSS Module analog
channel offset
Displays/calibrates the LSS Module analog
channel gain
Displays/calibrates the LSS Module analog
channel offset
Displays/calibrates the LSS Module excitation measurement gain
Displays/calibrates the LSS Module internal
temp sensor
– JLG Lift –
550 LBS
(378 KGS)
Single or
Dual
Extensions
2083 LBS
(945 KGS)
1042 LBS
(473 KGS)
1320 LBS
(599 KGS)
0 LBS
(0KGS)
0 LBS
(0KGS)
MegaDeck1574 LBS
(714 KGS)
0 LBS
(0KGS)
2 SEC
2 SEC
2 SEC
2 SEC
3 SEC
3 SEC
3 SEC
3 SEC
5 SEC
5 SEC
5 SEC
5 SEC
0 LBS
(0KGS)
X
X
X
X
X
X
X
X
X
X
2-5
SECTION 2 - OPERATION - (LE, MRT, RTS)
2.5
MACHINE SETUP MENU (LE, MRT &
RTS)
2.6
The Machine Setup Menu is used to configure the Load
Sensing System for application on a particular JLG model,
and select the desired force units (i.e. pounds or kilograms). In addition, the technician can trigger the LSS
Module to restore Defaults to all Personalities Parameters
by changing the MODEL to any other selection, and then
re-selecting proper model.
Note that Diagnostics and Personalities Menus change
based on MODEL Parameter (some displays are suppressed).
CALIBRATION MENU (LE, MRT & RTS)
The Calibration Menu is used to zero the Empty Platform
weight.
To access the Calibration Menu, use the LEFT and RIGHT
Arrow keys to select CALIBRATION from the Top Level
Menu. Press the ENTER key to view the menu.
NOTE: The Calibration Menu is not available in Access
Level 2.
Upon entry to the Calibration Menu, the LSS Module shall
communicate to the Analyzer:
To access the Machine Setup Menu, use the LEFT and
RIGHT Arrow keys to select MACHINE SETUP from the
Top Level Menu. Press the ENTER key to view the menu.
Press the LEFT and RIGHT Arrow keys to view the displays.
The following table details the structure of the Machine
Setup Menu, and describes the meaning of each parameter.
Table 2-4. Machine Setup Menu
Parameter
(Displayed on
Analyzer 2nd
Line)
Parameter Value
(Displayed on
Analyzer 2nd Line)
Description
MODEL:
=BOOM LIFT
=4069LE
=3369LE
=500RTS
=260MRT
=Scissor
Displays/adjusts Model Selection. Must be set to proper
model for this application.
(Scissor available after software V7.00)
UNITS:
=LBS
=Kg
Displays/adjusts global force
units
CALIBRATE:
YES:ENTER, NO:ESC
Pressing the ESC key will return the user to the top level
menu and not disturb the prior calibration information.
2-6
– JLG Lift –
3124288
SECTION 2 - OPERATION - (LE, MRT, RTS)
Pressing the ENTER key will confirm that the platform is
empty (except for factory-installed options outside the
Rated Load). The LSS Module will calculate the total of all
load cell readings and ensure that the total is greater than
minimum calibration value, but less than maximum calibration value. If successful, the Analyzer will show the following:
If the empty platform weight is less than minimum calibration value, the calibration attempt will be unsuccessful and
the Analyzer will show the following:
CALIBRATE:
< MIN CAL
If the empty platform weight is greater than maximum calibration value, the calibration attempt will be unsuccessful
and the Analyzer will show the following:
CALIBRATE:
COMPLETE
Table 2-5. Calibration Values
MODELS
4069LE
3969LE
500RTS
260MRT
Minimum Calibration Value
850 lb
(385 kg)
850 lb
(385 kg)
1100 lb
(499 kg)
750 lb
(340 kg)
Maximum Calibration Value
1425 lb
(646 kg)
1425 lb
(646 kg)
2950 lb
(1338 kg)
1250 lb
(567 kg)
CALIBRATE:
> MAX CAL
3124288
– JLG Lift –
2-7
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3,5,10secretary
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– JLG Lift –
E
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SECTION 2 - OPERATION - (LE, MRT, RTS)
3124288
SECTION 2 - OPERATION - (LE, MRT, RTS)
2.7
JLG WORKSTATION IN THE SKY™
ACCESSORIES
Table 2-6. LSS Module Guidelines
The Load Sensing System must be configured for proper
operation with JLG Sky™ Accessories. Calibration of the
Load Sensing System can be performed with the Accessory mounted in the platform.
A platform-mounted accessory slightly reduces the
amount of load that can be carried before the vehicle
becomes overloaded. This extra load must be accounted
for to enable the accessory to be mounted during Calibration.
A De-Rating is provided for JLG Sky Accessories via decal
and/or the JLG Workstation in the SkyTM Accessory Manual. This De-Rating must be entered into the LSS Module’s ACC’Y Personality to cause the system to accurately
indicate overload (by the De-Rating factor).
PERSONALITY
SETTING
ACC’Y
300 lb (136 kg)
Procedurally, the Accessory should be mounted to the
platform and the LSS Module’s ACC’Y Personality should
be set using the guidelines above. Calibration should be
performed as outlined in this manual. During Testing &
Evaluation, it should be noted that the LSS will declare
Overload with less platform load (by the amount of the DeRating).
Example: Consider that of the Easi-Cladder™ with a DeRating of 300 lbs (136 kg) mounted on a 500RTS. Without
De-Rating, the Load Sensing System will declare on Overload at 2750 lb (1247 kg), which is 110% of its 2500 lb
(1134 kg) rated Load. When the De-Rating for Easi-Cladder™ is entered into the ACC’Y Personality, the LSS will
declare Overload 300 lb (136 kg) earlier (2450 lb or 1111
kg).
3124288
– JLG Lift –
2-9
SECTION 2 - OPERATION - (LE, MRT, RTS)
NOTES:
2-10
– JLG Lift –
3124288
SECTION 3 - OPERATION - (ES, RT)
SECTION 3. OPERATION - (ES, RT)
3.1
CONNECTING THE JLG CONTROL
SYSTEM ANALYZER (ES & RT)
3.2
1. Connect the cable supplied with the Analyzer to the
host control system located at the ground controlstation on both the ES and the RT models. There is
also an alternate connection on the under side of the
platform control station on the RT. Connect the
remaining end of the cable to the analyzer.
NOTE: The cable has a four-pin connector at each end of
the cable; The cable cannot be connected backwards.
2. Power-up the Control System by turning the key to
the Platform or Ground position and pulling both
emergency stop buttons.
HELP MENU & FAULT CODES (ES & RT)
The Help Menu is a troubleshooting tool to communicate
detected System Faults to the technician. The following
table documents the Faults for the Load Sensing System.
To access the Help Menu, use the LEFT and RIGHT arrow
keys to select HELP: PRESS ENTER from the Top Level
Menu. Press the ENTER key to view the menu.
When accessing the Help Menu, the JLG Analyzer will display EVERYTHING OK if the platform is not overloaded
and no difficulties are detected. Otherwise, the JLG Analyzer will display OVERLOADED.
In the event of difficulty, the user can press ENTER again
to display Logged Help, which is a record of the last 16
Fault Messages. The following table lists each Help/
Logged Message, the Flash Code (for each Fault, the
module will flash the two-digit code on its LED) triggered
by the Fault, and a Description of the Situation (cause).
Table 3-1. LSS Fault Codes (LE, MRT and RTS)
Help/Logged Message
Flash
Code
Description of Situation
PLATFORM OVERLOADED
2-5
The platform load measured at the Load Sensing System is excessive. Functions from the platform control are prevented, and functions from the ground control may be prevented, depending on machine.
BATTERY TOO HIGH
4-4
Incoming Supply Voltage >34.0 Vdc. The control system’s battery voltage is too high. This may be due to over-charging or improper charger operation.
BATT TOO LOW
4-4
Incoming Supply Voltage <9.0 Vdc. The control system’s battery voltage is too low due to excessive electrical load or
discharge. This may compromise ability to predict weight. Recharge batteries or check for damaged batteries.
CANBUS FAILURE: LSS
MODULE
6-6
The control system failed to receive messages from the LSS Module. Check wiring at the LSS Module and along scissor arms leading up to platform.
CELL #1 ERROR
8-1
Cell #1’s Bridge <2V, >3V, or could not read Cell #1’s Internal Memory. This situation indicates damage to the sensor or its wiring.
CELL #2 ERROR
8-2
Cell #2’s Bridge <2V, >3V, or could not read Cell #2’s Internal Memory. This situation indicates damage to the sensor or its wiring.
CELL #3 ERROR
8-3
Cell #3’s Bridge <2V, >3V, or could not read Cell #3’s Internal Memory. This situation indicates damage to the sensor or its wiring.
CELL #4 ERROR
8-4
Cell #4’s Bridge <2V, >3V, or could not read Cell #4’s Internal Memory. This situation indicates damage to the sensor or its wiring.
WATCHDOG RST
9-1
Microprocessor’s Watchdog Timer Triggered. This is an indication that the LSS Module has been exposed to excessive electrical noise, or has experienced a hardware difficulty.
EEPROM ERROR
9-2
Memory used to retain Personality/Machine Setup/Calibration has been corrupted and must be reset by verifying all
entries and re-calibrating. After resolution, re-cycle power to clear difficulty.
LSS NOT CALIBRATED
9-3
Calibration has not been successfully completed. A new LSS Module will display this message until properly calibrated.
LSS INTERNAL ERROR
- PIN EXCITATION
9-9
Pin excitation <4.25 V. The sensors may be excessively loading the excitation supply, or the LSS Module may have
hardware difficulty.
LSS INTERNAL ERROR
- DRDY MISSING FROM
A/D
9-9
DRDY Interrupt from LSS Module’s A/D converter missing. This may indicate an LSS Module hardware difficulty.
3124288
– JLG Lift –
3-1
SECTION 3 - OPERATION - (ES, RT)
3.3
DIAGNOSTIC MENU (ES & RT)
The Diagnostic Load Menu is another troubleshooting tool
for the Load Sensing System. Sensor and status information is presented in real-time for the technician.
To access the Diagnostic Menu, use the LEFT and RIGHT
Arrow keys to select DIAGNOSTICS from the Top Level
Menu. Press the ENTER key to select the menu.
NOTE: The Diagnostic, Load menu is not available when the
LSS is not enabled. (Machine Setup, Load is set to
0=Not Installed
Press the LEFT and RIGHT Arrow keys to view the load
sub-menus and press the enter key. Once in the load submenu, press the LEFT and RIGHT arrow keys to view the
various displays.
The table below details the structure of the Diagnostic,
Load Menu, and describes the meaning of each piece of
information presented.
Table 3-2. Diagnostic Menu Descriptions (ES & RT)
Diagnostics Menu
(Displayed on Analyzer 1st Line)
Parameter (Displayed
on Analyzer 2nd Line)
Parameter Value
(Displayed on Analyzer 2nd
Line)
Description
LOAD:
PLTLOAD
+XXXX Kg
Displays (Total Measured Force – Empty Platform
Calibration), in kilograms
PLTGROS
+XXXX Kg
Displays Total Measured Force (Sum of Pins 1 thru 4
LOAD) in kilograms
OVERLOADED?
3.4
Yes / No
Displays Current LSS Module Overload Status
CELL 1
+XXXX Kg
Displays Calibrated Cell Reading in kilograms
CELL 2
+XXXX Kg
Displays Calibrated Cell Reading in kilograms
CELL 3
+XXXX Kg
Displays Calibrated Cell Reading in kilograms
CELL 4
+XXXX Kg
Displays Calibrated Cell Reading in kilograms
ANALYZER
VX.XXXX
Displays Analyzer Software Version
PERSONALITIES (ES & RT)
The following parameter in the PERSONALITIES, LOAD
menu adjust performance of the LSS. All adjustments
must be made in Access Level 1 (33271).
REFER TO JLG WORKSTATION IN THE SKY™ ACCESSORIES IN
THIS SECTION WITH REGARD TO SETTING THE ACCY PERSONALITIES.
Table 3-3. Personalities (ES & RT)
Submenu (Displayed on
analyzer1st LIne)
LOAD:
3-2
Parameter (Displayed on
analyzer 2nd line)
Description
ACC’Y XXXX KG
Displays/adjusts a derating
for accessories
OVR DBNCE 3 S
Displays/ adjusts the
debounce delay before an
overload
OVR HOLD 5 S
Displays/adjusts the minimum delay before an overload
can be released.
– JLG Lift –
3124288
SECTION 3 - OPERATION - (ES, RT)
3.5
MACHINE SETUP MENU (ES & RT)
3.6
The LOAD submenu within the machine setup menu is
used to configure the LSS. To access the Machine Setup,
Load menu, use the Left and Right arrow keys to select
MACHINE SETUP from the Top Level Menu. Press the
ENTER key to select the menu. Press the Left and Right
arrow keys to select LOAD from the MACHINE SETUP
menu. Press the Enter key to view the submenu.
The following table details the structure of the load submenu and describes the meaning of the parameter.
Table 3-4. Machine Setup
Submenu
(Displayed on
analyzer1st LIne)
Parameter
(Displayed on
analyzer 2nd line)
CALIBRATION MENU (ES & RT)
The Load submenu within the Calibration Menu is used to
zero the Empty Platform weight.
To access the Calibration Load Menu, use the LEFT and
RIGHT Arrow keys to select CALIBRATION from the Top
Level Menu. Press the ENTER key to select the menu.
Press the LEFT and RIGHT arrow keys to select LOAD
from the CALIBRATION menu. Press the ENTER key to
view the submenu.
NOTE: The Calibration Menu is not available in Access
Level 2.
Upon entry to the Calibration, Load Menu, the analyzer
will display:
Description
0 = NOT INSTALLED
LOAD:
1 = CUTOUT PLT
Displays/adjusts the
LSS Module
2 =CUTOUT ALL
CALIBRATE:
YES:ENTER, NO:ESC
Pressing the ESC key will return the user to the top level
menu and not disturb the prior calibration information.
3124288
– JLG Lift –
3-3
SECTION 3 - OPERATION - (ES, RT)
Pressing the ENTER key will confirm that the platform is
empty (except for factory-installed options outside the
Rated Load). The LSS Module will calculate the total of all
load cell readings and ensure that the total is greater than
minimum calibration value, but less than maximum calibration value. If successful, the Analyzer will show the following:
If the empty platform weight is less than minimum calibration value, the calibration attempt will be unsuccessful and
the Analyzer will show the following:
CALIBRATE:
< MIN CAL
If the empty platform weight is greater than maximum calibration value, the calibration attempt will be unsuccessful
and the Analyzer will show the following:
CALIBRATE:
COMPLETE
Table 3-5. Calibration Values
MODELS
ES
RT
Minimum Calibration Value
45 KG
(99 LB)
225 KG
(496 LB)
Maximum Calibration Value
275 KG
(606 LB)
1020KG
(2249 LB)
CALIBRATE:
> MAX CAL
3-4
– JLG Lift –
3124288
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3124288
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Figure 3-1. Module Analyzer Flow Chart
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– JLG Lift –
E
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SECTION 3 - OPERATION - (ES, RT)
3-5
SECTION 3 - OPERATION - (ES, RT)
NOTES:
3-6
– JLG Lift –
3124288
SECTION 4 - OPERATION - (RS)
SECTION 4. OPERATION - (RS)
4.1
CONNECTING THE JLG CONTROL
SYSTEM ANALYZER (RS)
4.2
1. Remove the compartment panel on the ground control side of the machine.
2. Disconnect the 4 pin connector which provides
power and information to the MDI Display.
3. Connect the cable supplied with the Analyzer to the
mating 4 pin connector that was just disconnected.
NOTE: The cable has a four-pin connector at each end of
the cable; The cable cannot be connected backwards.
4. Power-up the Control System by turning the key to
the Ground Control position and pull the Ground
emergency stop button.
HELP MENU & FAULT CODES (RS)
The Help Menu is a troubleshooting tool to communicate
detected System Faults to the technician. The following
table documents the Faults for the Load Sensing System.
To access the Help Menu, use the LEFT and RIGHT arrow
keys to select HELP: PRESS ENTER from the Top Level
Menu. Press the ENTER key to view the menu.
When accessing the Help Menu, the JLG Analyzer will display EVERYTHING OK if the platform is not overloaded
and no difficulties are detected. Otherwise, the JLG Analyzer will display OVERLOADED.
In the event of difficulty, the user can press ENTER again
to display Logged Help, which is a record of the last 16
Fault Messages. The following table lists each Help/
Logged Message, the Flash Code (for each Fault, the
module will flash the two-digit code on its LED) triggered
by the Fault, and a Description of the Situation (cause).
Table 4-1. LSS Fault Codes (RS ONLY)
HELP/LOGGED MESSAGE
Everything OK
FLASH
CODE
DESCRIPTION OF SITUATION
LED ON The "Normal" Help Message
PLATFORM OVERLOADED
2-5
While the Load Sensing System is enabled, the Platform Load measured by the Load Sensing System is
excessive. Functions from Platform Control are prevented, and functions from Ground Control may be prevented, depending on machine configuration (Markets other than Japan).
For the Japanese Market, only Lift Up is prevented and Drive (at creep speed) is allowed in the stowed position.
CANBUS FAILURE - LSS
ANGLE SENSOR
6-6
The Control System Failed to receive messages from the Angle Sensor. Check wiring to the Angle Sensor.
LSS PRESSURE SENSOR DISAGREEMENT
8-2
Pressure Sensor 1 and Pressure Sensor 2 do not agree. The system shall assume the machine is overloaded
until the sensors agree.
Using the Analyzer LOAD submenu under DIAGNOSTICS check PRES1 and PRES2 readings. They must
agree within 75 PSI. With the safety prop engaged check to ensure that the appropriate voltage is being supplied to both sensors and that the wiring and connections are intact. The voltage between pins A and B should
read +5V +/- 0.5V with the machine turned on. If the voltage supplied is correct, replace both transducers.
LSS ANGLE SENSOR - DIRECTION DISAGREEMENT
8-2
The Angle sensors change in reading does not agree with the direction of machine motion (lift up).This indicates that the direction of movement of the platform does not agree with the angle sensors change in output.
Ensure that the angle sensor is installed properly and that the lever arm is not damaged.
LSS ANGLE SENSOR OUT OF RANGE HIGH
8-2
The Angle Sensor's reading when the machine is at maximum elevation does not fall within the high end
acceptable range. The Angle Sensors reading must be less than or equal to 245 counts at maximum elevation.
Ensure that the Angle Sensor is mounted properly.
LSS ANGLE SENSOR OUT OF RANGE LOW
8-2
The Angle Sensor's reading when the machine is stowed does not fall within the low end acceptable range.
The Angle Sensors reading must be greater than or equal to 5 counts with the platform stowed.
Ensure that the Angle Sensor is mounted properly.
LSS ANGLE SENSOR HAS
NOT BEEN CALIBRATED
8-2
The Angle Sensor has never been calibrated and the control system assumes that the platform is overloaded.
Calibrate the Angle Sensor using the CALIBRATION: ANGLE submenu to clear the message.
3124288
– JLG Lift –
4-1
SECTION 4 - OPERATION - (RS)
4.3
DIAGNOSTIC MENU (RS)
The Diagnostic Load and Angle menu's are another troubleshooting tool for the Load Sensing System. Sensor
and status information is presented in real-time for the
technician.
To access the Diagnostic Menu, use the LEFT and RIGHT
Arrow keys to select DIAGNOSTICS from the Top Level
Menu. Press the ENTER key to select the menu.
NOTE: The Diagnostic Load and Angle menu's are not available when the LSS is not enabled. (Machine Setup,
Load is set to 0=Not Installed
Press the LEFT and RIGHT arrow keys to view the load
and angle sub-menu and press the enter key. Once in the
load and angle submenu, press the LEFT and RIGHT
arrow keys to view the various displays.
The table below details the structure of the Diagnostic,
Load Menu and Angle Menu, and describes the meaning
of each piece of information presented.
Table 4-2. Diagnostic Menu Descriptions (RS)
DIAGNOSTICS MENU
(Displayed on Analyzer 1st Line)
LOAD:
PARAMETER
(Displayed on Analyzer
2nd Line)
PARAMETER VALUE
(Displayed on Analyzer 2nd
Line)
DESCRIPTION
OVERLOADED?
Yes/No
Displays the current LSS state.
PRES1
xxxxPSI
Displays the actual pressure reading from Pressure Transducer #1.
PRES2
xxxxPSI
Displays the actual pressure reading from Pressure Transducer #2.
LOAD: PRES DIF
P1-P2
xxxxPSI
Displays the absolute pressure difference
between transducer 1 and transducer 2. PRES DIF
= ABSOLUTE(PRES1 - PRES2).
LOAD: PRES DIF
OVLD-P1
xxxxPSI
Displays the pressure difference between Lift Up
or Lift Down Pressure Overload Limits (depending
on motion) and Actual Pressure.
MARGIN = Lift Up Pressure Overload Limit PRES1 or MARGIN = Lift Down Pressure Overload Limit - PRES1.
LOAD: TOCLEAROVLD
PRES
xxxxPSI
Displays the amount of pressure that must be
reduced before the overload condition is resolved.
XXX = PRES1 - (OVRPRES - PRESREDUCE).
When an overload condition does not exist this
value shall be 0.
ANGLE:
MINANGLE
xxx
Displays the angle sensors MINANGLE (stowed)
value based on angle sensor calibration.
MAXANGLE
xxx
Displays the angle sensors MAXANGLE (max elevation) value based on angle sensor calibration.
ANGLERANGE
xxx
Displays the difference between MAXANGLE and
MINANGLE.
ANGLERANGE = MAXANGLE - MINANGLE.
ANGLE
xxx
Displays the actual angle sensor count value at all
times.
4-2
– JLG Lift –
3124288
SECTION 4 - OPERATION - (RS)
4.4
PERSONALITIES MENU (RS)
4.5
The following parameter in the PERSONALITIES, LOAD
menu adjust performance of the LSS. All adjustments
must be made in Access Level 1 (33271).
CALIBRATION MENU (RS)
NOTE: The Load Sensing System cannot be calibrated without first calibrating the machines Angle Sensor.
Angle Sensor Calibration (RS Only)
Table 4-3. Personalities Menu Description (RS)
To access the Calibration Angle Menu, use the LEFT and
RIGHT Arrow keys to select CALIBRATION from the Top
Level Menu. Press the ENTER key to select the menu.
SUBMENU
(Displayed on
Analyzer 1st line)
PARAMETER
(Displayed on
Analyzer 2nd Line)
LOAD:
OVR DBNCE 0.3S
Displays/Adjusts the
debounce delay for an
overload.
OVR HOLD 5.0S
Displays/Adjusts the
minimum delay
before an overload
can be resolved.
DESCRIPTION
Press the LEFT and RIGHT arrow keys to select ANGLE
from the CALIBRATION menu. Press the ENTER key to
view the submenu.
Should the Analyzer read CAL ANGLE:FAIL at any time
during the calibration procedure, reference the table
below for the failure listed by the Analyzer.
NOTE: The Calibration Menu is not available in Access
Level 2.
Upon entry to the Calibration, ANGLE Menu, the analyzer
will display:
CAL ANGLE:
YES:ENTER NO:ESC
CAL ANGLE:
YES:ENTER, NO:ESC
Pressing the ESC key will return the user to the top level
menu and not disturb the prior calibration information.
3124288
– JLG Lift –
4-3
SECTION 4 - OPERATION - (RS)
Pressing the Enter key will request that the technician
engage lift up until the platform has reached maximum
height:
If the Angle Sensors range from stowed to maximum
height is acceptable the Analyzer will display the following:
CAL ANGLE:
COMPLETE!
CAL ANGLE:
LIFT TO MAX
CAL ANGLE:
CAL ANGLE:
LIFT TO MAX
COMPLETE!
If the Angle Sensor's reading at maximum height is
acceptable the Control System will record the sensors
value and Analyzer will display the following.
CAL ANGLE:
LOWER TO STOWED
CAL ANGLE:
LOWER TO STOWED
4-4
– JLG Lift –
3124288
SECTION 4 - OPERATION - (RS)
Table 4-4. Angle Sensor Calibration Failure Troubleshooting (RS Only)
ANGLE SENSOR CALIBRATION FAILURE
(Displayed on Analyzer 2nd Line)
DESCRIPTION
MAX NOT IN RANGE
The Angle Sensors upper limit is not acceptable. It must fall within +/- 35 counts of 210
counts.
MAXANGLE TOO HIGH
The MAXANGLE value was greater than 245
counts. The MAXANGLE value must be a number less than or equal to 245.
LOW NOT IN RANGE
The Angle Sensors lower limit is not acceptable.
It must fall within +/- 35 counts of 40 counts.
MINANGLE TOO LOW
The MINANGLE value was less than 5 counts.
The MINANGLE value must be a number more
than or equal to 5.
INVALID RANGE
The sensors range from the platform stowed
position to the platform's maximum elevation
position was not acceptable.
CAL FAIL!
The technician has pressed ESC on the Analyzer during the calibration routine
4.6
LOAD SENSING SYSTEM CALIBRATION
(RS ONLY)
CHECK
• Check the Angle Sensor to ensure it is
installed properly.
• Ensure that the Angle Sensors lever arm is
installed properly.
• Check the Angle Sensor to ensure it is
installed properly.
• Ensure that the Angle Sensors lever arm is
installed properly.
• Check the Angle Sensor to ensure it is
installed properly.
• Ensure that the Angle Sensors lever arm is
installed properly.
• Check the Angle Sensor to ensure it is
installed properly.
• Ensure that the Angle Sensors lever arm is
installed properly.
• "Check the Angle Sensor to ensure it is
installed properly.
• "Ensure that the Angle Sensors lever arm is
installed properly.
Upon entry to the Calibration, LOAD Menu, the analyzer
will display:
To access the Calibration Load Menu, use the LEFT and
RIGHT Arrow keys to select CALIBRATION from the Top
Level Menu. Press the ENTER key to select the menu.
Press the LEFT and RIGHT arrow keys to select LOAD
from the CALIBRATION menu. Press the ENTER key to
view the submenu. Should the Analyzer read CAL
LOAD:FAIL at any time during the calibration procedure,
reference the table below for the failure listed by the Analyzer.
CAL LOAD:
YES: ENTER NO: ESC
NOTE: The Calibration Menu is not available in Access
Level 2.
PRIOR TO LOAD SENSING SYSTEM CALIBRATION ENSURE THAT
THE MACHINE HAS BEEN PLACED ON LEVEL GROUND, THE
HYDRAULIC FLUID IS WITHIN THE ACCEPTABLE RANGE, THE
TEMPERATURE IS GREATER THAN 32 DEGREES F, AND THE
BATTERIES ARE FULLY CHARGED.
CAL LOAD:
YES:ENTER, NO:ESC
Pressing the ESC key at any time will return the user to the
top level menu and not disturb the prior calibration information.
Pressing the Enter key will ensure that appropriate Calibration Weight, 110% rated load, has been placed in the
3124288
– JLG Lift –
4-5
SECTION 4 - OPERATION - (RS)
center of the platform. The Analyzer will display the following.
Pressing the Enter key again will make the Analyzer display the following which means engage lift down until the
platform becomes stowed.
CAL LOAD:
110% LOAD CENTER?
CAL LOAD:
LOWER TO STOWED
CAL LOAD:
CAL LOAD:
110%LOAD,CENTER?
LOWER TO STOWED
Pressing the Enter Key again will make the Analyzer display the following which means engage lift up from the
ground panel until the platform reaches maximum elevation.
If the Load Calibration is successful the Analyzer will display the following.
CAL LOAD:
COMPLETE!
CAL LOAD:
LIFT TO MAX ELEV
CAL LOAD:
CAL LOAD:
COMPLETE!
LIFT TO MAX ELEV
4-6
– JLG Lift –
3124288
SECTION 4 - OPERATION - (RS)
Table 4-5. Load Calibration Failure Troubleshooting (RS Only)
LOAD CALIBRATION FAILURE
(Displayed on Analyzer 2nd Line)
NOT IN GND MODE
DESCRIPTION
The machine is not in Ground Mode.
CHECK
• Set the key switch so that the machine is in
Ground Mode.
• The machine must be in ground Mode for
Load calibration.
CAL ANGLE
The Angle Sensor has not been calibrated.
• Navigate to the Calibrations menu and
enter the Angle submenu to perform Angle
Sensor calibration.
• The Angle sensor must be calibrated
before Load calibration can occur.
PLAT NOT STOWED
The machines platform is not stowed.
• Ensure that the platform is stowed and perform the Load calibration again.
MOTION STOPPED
The platform stopped moving during calibration.
• The technician let go of the lift up switch
before the machine reached maximum elevation during "CAL LOAD: LIFT TO MAX
ELEV".
CAL FAIL
The technician has pressed ESC on the Analyzer during the calibration routine.
3124288
– JLG Lift –
4-7
SECTION 4 - OPERATION - (RS)
NOTES:
4-8
– JLG Lift –
3124288
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
SECTION 5. SERVICE - (LE, MRT, RTS, ES, RT)
5.1
DESCRIPTION
The system consists of the LSS Module, four Shear Pin
Load Cells (sensors), Wire Harness, and various brackets
and fasteners. The LSS Module is mounted beneath the
platform on a bracket. The Shear Pin Load Cells mount
between the platform and the arm structure in such a way
that all support force for the platform is applied through
them (for measurement). The four Shear Pin Load Cells
plug directly into the LSS Module. The Wire Harness connects the LSS Module to the Host Control System.
1
NOTE ORIENTATION OF PIN ARROW,
POINTED AWAY FROM PLATFORM
2
8
7
6
3
5
4
1. Load Cell (Typical 4 Corners)
2. System Interface - Power & Digital - J1
3. System Interface Communication - J2
4. Indicator Light
5. Rear Right Load Cell - J8
6. Rear Left Load Cell - J7
7. Front Right Load Cell - J6
8. Front Left Load Cell - J5
Figure 5-1. Load Sense Module
3124288
– JLG Lift –
5-1
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
5.2
CALIBRATION
6. Execute a Calibration via the JLG Analyzer. Proceed
to the Analyzer’s CALIBRATION top level menu and
press ENTER. Press ESC to abort a calibration or
ENTER to calibrate (tare). If successful, the Analyzer
will display “COMPLETE”. If unsuccessful, a message will be displayed that will help lead to a resolution (reference the Troubleshooting section of this
manual). Press ESC to return to the top level menu.
Procedure
1. Plug the JLG Analyzer into the LSS Module on the
LE, MRT and RTS or the Host Control System on the
ES and RT and enter the Access Level 1 Password.
Do not confuse the Host Control System and LSS
Module’s Analyzer Connections. Proceed to the
ACCESS LEVEL menu and enter the Access Level 1
Password (33271).
2. Park the vehicle on a level surface. The platform
should be fully stowed and level within ± 5° (both
directions).
Testing & Evaluation
Refer to the Troubleshooting section of this manual if the
Load Sensing System fails to meet these guidelines.
3. Configure the LSS Module for the proper model and
Desired Units. On LE, MRT and RTS, proceed to the
LSS Module’s MACHINE SETUP, MODEL sub-menu
and select “MODEL=4069LE, 3369LE, 500RTS, or
260MRT”. Press the RIGHT ARROW to view the
Units Selection. Select “UNITS=LBS” for platform
load measurement in Pounds, and “UNITS=KG” for
measurement in Kilograms.
EARLY RT’S REQUIRE A CONFIGURATION TO THE LSS MODULE.
PLUG THE JLG ANALYZER INTO THE MODULE’S CONNECTION
BENEATH THE DECKAND ENTER THE ACCESS LEVEL 1 PASSWORD (33271). UNDER MACHINE SETUP ENSURE THAT
MODEL=260MRT.
4. Remove everything except JLG Accessories from
the Platform. Empty the platform to allow the Load
Sensing System to record its weight during calibration. All tools, debris, and customer-installed devices
shall be removed. Permanently-fixed JLG Accessories shall remain and their contribution toward Rated
Load will be accounted for in the next step.
1. Plug the JLG Analyzer into the LSS Module (LE,
MRT and RTS) or the Host Control System (ES and
RT).
2. Park the vehicle on a level surface. The platform
should be fully stowed and level within ± 5° (both
directions).
3. Observe the Empty Platform Weight. Proceed to the
DIAGNOSTICS, PLTLOAD sub-menu and observe
the measured platform load. All tools, debris, and
customer-installed devices shall be removed during
evaluation. Ideally, the PLTLOAD should be zero but
can vary +15lbs (± 7kg). Further, the reading
should be stable and should not vary by more than
+2lbs (±1kg) (unless there is heavy influence from
wind or vibration).
4. Use the Technician’s Weight to Evaluate. The technician should enter the platform and record the PLTLOAD reading while standing in the center of the
platform, and then each corner. The average of the
readings should be the estimated weight of the technician. The range of the readings should be no more
than 40lbs (18kg) (max PLTLOAD reading – min PLTLOAD reading).
5. Configure the LSS Module for JLG Accessories. The
contribution of each permanently-fixed JLG Accessory toward Rated Load must be determined. JLG
Accessories are decaled with their effective contribution toward Rated Load. If this decal is missing, reference the appropriate manual for the JLG
Accessory. Once determined, the contributions of all
permanently-fixed JLG Accessories mounted in the
platform of the vehicle shall be added together and
entered in the Analyzer’s PERSONALITIES, ACC’Y
display (using the proper units).
5-2
– JLG Lift –
3124288
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
5. Confirm Host Control System Warnings and Interlocks. Using the vehicle’s keyswitch, select Platform
Mode and power-up. Start the vehicle’s engine (If
equipped) and ensure that all controls are functional
and the Load Sensing System’s Overload Visual and
Audible Warnings are not active. Simulate an Overload by unplugging the Shear Pin Load Cell connected to J5 on the LSS Module. The Overload
Visual Warning should flash, and the Audible Warning (at Platform and Ground) should sound for 5
seconds On, and 2 seconds Off. With the engine
running (If equipped), all platform control should be
prevented. Cycle the Platform EMS to stop the
engine and then power-up again. The Overload
Visual and Audible Warning should continue. Install
the disconnected Shear Pin Load Cell back in J5 on
the LSS Module. The Overload Visual and Audible
Warnings should cease and normal control function
should return. Switch the vehicle’s keyswitch to
Ground Mode and repeat the above procedure. The
Overload Visual Warning at the Ground Controls
should flash, and the Audible Warning (at Platform
and Ground) should sound for 5 seconds On, 2 seconds Off. However, the controls should remain functional when using the engine (if the Host Controls
System’s MACHINE SETUP, LOAD is set to “2=CUTOUT PLT”. If set to “3=CUTOUT ALL”, then Ground
Controls will be prevented when using the platform).
Re-fit the Shear Pin Load Cell connector to J5 on the
LSS Module and carefully tighten by hand, and then
with a small pair of locking pliers to seat the O-ring
seal.
3124288
– JLG Lift –
6. Confirm Load Sensing System Performance with
Calibrated Weights. Operate the vehicle from
Ground Control and place the platform in the fully
stowed position for safety. Place 120% of the
machines rated load in the center of the platform
and ensure that the overload visual and audible
warnings are active. Reduce the platform load to
100% rated load and ensure that the warnings are
not active. For vehicles with multiple capacities,
evaluate each operating mode with the proper rated
load.
5-3
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
5.3
TROUBLESHOOTING
The following tables are furnished to provide possible resolutions for common difficulties. Difficulties are classified
as General, Calibration, Measurement Performance, and
Host System Functionality.
Table 5-1. LSS Troubleshooting Chart - General
Difficulty
Possible Resolution
JLG Analyzer does not display The JLG Analyzer is failing to communicate with the LSS Module, but the LSS Module is
“HELP: PRESS ENTER” when powered (indicated by module’s LED). Investigate JLG Analyzer serial communication and
connected to LSS Module’s power supply connections.
connection, but the module’s
1. If the Analyzer displays “CONNECTING…” or “CONNECTION ERROR” after a short
LED is lit or flashing.
interval, examine the Analyzer harness on J2. J2-2 should connect to Pin 3 on the
Analyzer, and J2-11 should connect to Pin 2.
2. If the Analyzer does not display anything (and there is no backlighting), examine the
Analyzer’s power supply. Remove the harness connection from J2 and ensure that
J2-1 has approximately 12V, and J2-12 is 0V. The harness should connect J2-1 to Pin
1 on the Analyzer, and J2-12 to Pin 4 on the Analyzer.
3. The JLG Analyzer is suspect. Substitute to determine cause of failure.
4. The LSS Module is suspect. Substitute to determine cause of failure.
LED on LSS Module does not The LSS Module is un-powered, a short exists, or the device is damaged.
light.
1. LSS Module’s power supply is improper. Check for the presence of approximately
12V on J1-1, and 0V on J1-2. The module’s power supply comes from the Platform
Console Box. Use to the Wiring Diagram to trace the conductors to their source.
2. There is a short circuit on the reference voltage present on J5-J8. Unplug the connectors one at a time and observe if the module begins to function after a particular
connection is removed. If so, carefully inspect the wiring between the module and
that sensor.
3. There is a short circuit on the pre-regulated supply for the JLG Analyzer present on
J2-1. Unplug J2’s connector and observe whether the module begins to function. If
so, examine the Analyzer harness for defect.
4. The LSS Module is suspect. Substitute to determine cause of failure.
5-4
– JLG Lift –
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SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Table 5-2. LSS Troubleshooting Chart - Calibration
Difficulty
Possible Resolution
JLG Analyzer displays
The LSS Module expected the empty platform to weight more for calibration.
“<MIN CAL” after attempt is
1. The platform is being supported by something other than the four Shear Pin Load
made to Calibrate.
Cells. This includes binding between the slide block/spacer bushing/arm tube
assembly (bushing should be free enough to rotate by hand). For proper operation,
the platform’s entire weight must be transferred through the Shear Pin Load Cells
and into the arm support structure for an accurate calibration.
2. The wrong Model Selection was made under the LSS Module’s MACHINE SETUP,
MODEL. This should be set to the proper MODEL (4069LE, 3369LE, 500RTS,
260MRT or SCISSOR). Improper selection may lead the LSS Module to expect different empty platform weights.
3. The calibration difficulty may be a result of a Measurement Performance issue.
Review the Possible Resolutions under that category.
JLG Analyzer displays “>MAX The LSS Module expects the empty platform to weigh less for calibration.
CAL” after attempt is made to
1. Tools, debris, or customer-installed accessories have not been removed before calCalibrate.
ibration. The LSS Module must tare an empty platform and its optional JLG Accessories.
2. The wrong Model Selection was made under the LSS Module’s MACHINE SETUP,
MODEL. This should be set to MODEL (4069LE, 3369LE, 500RTS, or 260MRT).
Improper selection may lead the LSS Module to expect different empty platform
weights.
3. The calibration difficulty may be a result of a Measurement Performance issue.
Review the Possible Resolutions under that category.
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– JLG Lift –
5-5
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Table 5-3. LSS Troubleshooting Chart - Measurement Performance
Difficulty
Possible Resolution
Empty Platform Weight (DIAG- The LSS Module is unable to properly measure the platform weight.
NOSTICS, PLTLOAD) is not
1. One of the Shear Pin Load Cells is not properly plugged into the LSS Module. Since
within +15lbs (±7kg) of zero.
the connectors seal with an O-ring and are located in a crowded area, it is possible
that the connectors are threaded together, but poor electrical contact is made.
or
Attempt to wiggle the molded portion of each connector on J5-J8. If properly tightPlatform Load readings (DIAGened, the molded portion should not move. Also, examined each Shear Pin Load
NOTICS, PLTLOAD) are unstaCell’s readings via the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD
ble by more than +2lbs (±1kg)
displays and determine if the readings are reasonable. Note that it is possible to have
(without the influence of vibraonly two sensors carrying all of the platform load due to fit between the platform and
tion or wind).
support structure (this is normal).
or
2. Wiring leading to one of the Shear Pin Load Cells is damaged. Examine each senThere are large variations in
sor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4,
Platform Load (DIAGNOSLOAD displays and determine if the readings are reasonable and responsive to slight
TICS, PLTLOAD) based on the
downward pressure above the sensor being viewed. Carefully inspect sensor wiring
location of the load. Tolerance
where it passes through cable clamps for signs of damage. Inspect wiring where
to variations is 40lbs (18kg) for
damage to the channel is apparent. If damage to the sensor’s cordset is found,
an evaluation using the technireplace the appropriate Shear Pin Load Cell since the cordset is not serviceable
cian’s weight, and +5% of
(connector is molded for moisture resistance; cordset is soldered into sensor
Rated Load when using calibeneath welded stainless steel cover). If damage to the sensors extension cordset is
brated weights.
found, unplug both ends and fit a replacement.
3. One of the Shear Pin Load Cells was not assembled properly during installation.
Examine each sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and determine if the readings are reasonable. It is
often helpful to apply slight downward pressure above the sensor being examined
and observe that its output increases (increasing force measurement; decreasing
means the sensor is mounted upside-down). Compare the order of assembly to the
detail on the Installation Drawing and ensure that the only contact between the platform and the support is through the sensor bodies (nothing else touches except
wires). Re-assemble according to print if necessary.
(continued)
5-6
– JLG Lift –
3124288
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Table 5-3. LSS Troubleshooting Chart - Measurement Performance
Difficulty
Possible Resolution
4. Damage to the platform or arm structure has occurred or one of the components is
out-of-tolerance.Twists in the platform, for instance, will cause huge off-axis forces to
be applied to the Shear Pin Load Cells, disturbing their primary measurement axis
readings. If Lift Up / Down is noisy or not smooth, examine this issue thoroughly.
Resolution is to replace the damaged or faulty component. Watch for Shear Pin Load
Cell damage (yield) as a result of this difficulty.
5. One of the Shear Pin Load Cells is contaminated by debris or moisture. Examine
each sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL
1-4, LOAD displays and determine if the readings are reasonable and stable (not
changing by more than +2lbs (±1kg) (without the influence of vibration or wind).
Lack of measurement stability is a key indication of contamination. Unplug the
appropriate connector (J5 is CELL 1, J6 is CELL 2, J7 is CELL 3, and J8 is CELL 4)
and inspect for dirt or moisture. Look carefully into the female connector on the sensor’s cordset for evidence of contamination. Debris should be brushed away with a
soft bristle brush (do not introduce any cleaners as they will leave conductive residue). Moisture should be allowed to evaporate or accelerated with a heat-gun (use
low heat and be carefully to not melt connector materials). Moisture intrusion into the
molded portion of the connector (capillary action into the wire bundle) or the Shear
Pin Load Cell itself will require replacement of the sensor.
6. One of the Shear Pin Load Cells has been mechanically damaged (yielded). Any
Shear Pin Load Cell that is physically deformed or has damage to one of the stainless steel covers should be replaced immediately. It is also possible to have invisible
mechanical damage resulting from an extreme overload (>4200lbs [>1900kg] for
1.25 in diam.; >5700 lbs or 2600 KG for 2 inch diam.). This can be detected by supporting the platform with an overhead crane and by removing the suspect sensor (no
weight resting on the Shear Pin Load Cell). Examine the sensor’s reading using the
JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and observe
whether the unloaded sensors read with +15lbs (±7kg) of zero (individually).
Replace sensors that read excessive force when physically unloaded.
7. The LSS Module is suspect. Interchange the Shear Pin Load Cell connections (J5J8) and observe the results via the JLG Analyzer. Proceed to the DIAGNOSTICS,
CELL 1-4, LOAD displays and observe the readings. If the problem seems to remain
with a particular sensor, carefully re-examine the issues above. If the problems
seems to remain with a particular LSS Module channel, substitute another module.
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– JLG Lift –
5-7
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Table 5-4. LSS Troubleshooting Chart - Host System Functionality
Difficulty
Possible Resolution
The Visual and Audible Overload Warnings fail to sound
when platform is loaded
beyond Rated Load, or when
simulated by unplugging a
Shear Pin Load Cell from the
LSS Module. Controls remain
functional at Platform and
Ground Control positions.
The Host Control System is failing to regard the overload signal from the LSS Module, or
the signal is shorted.
1. The Load Sensing System must be enabled within the Host Control System. Plug
the JLG Analyzer into the Host Control System, enter the Access Level 1 password
(33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “CUTOUT PLT” should be displayed for European Community compliance (platform controls prevented during overload, ground controls remain operational). In country- or
customer-specific circumstance, the selection “3=CUTOUT ALL” is used (platform
and ground controls prevented during overload).
2. (LE, MRT and RTS) - The signal between the LSS Module and the Host Control System is shorted. The Platform Module’s J1-20 is an input, and it connected to the J15 output on the LSS Module To examine the status of this signal, plug the JLG Analyzer into the Host Control System, enter the Access Level 1 password (33271), and
examine the DIAGNOSTICS, SYSTEM, LOAD display. The display will indicate “OK”
when the Platform Module’s input is energized (approximately 12V), and “OVERLOADED” when it is de-energized (0V). Refer to the Wiring Diagram for Load Sensing System for details
3. Observe the LSS Module’s assessment of overload using the JLG Analyzer plugged
into the LSS Module’s connection. Proceed to the DIAGNOSTICS, OVERLOADED?
display. The display should indicate “OVERLOADED? N” when the platform is
empty, and “OVERLOADED? Y” when the platform is overloaded. If the assessment
is improper, the difficulty may be a result of a General or Measurement Performance
issue. Review the Possible Resolutions under those categories.
4. (LE, MRT and RTS) - If the LSS Module’s J1-5 Output does not appears to coincide
with the DIAGNOSTICS, OVERLOADED? display, then the LSS Module is suspect.
Substitute to determine cause of failure.
5-8
– JLG Lift –
3124288
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Table 5-4. LSS Troubleshooting Chart - Host System Functionality
Difficulty
Possible Resolution
The Visual and Audible Over- The LSS Module is un-powered, un-calibrated, or is experiencing a Measurement Perforload Warnings sound even mance difficulty. Alternately, the Host Control System is not receiving the proper signal from
when the platform is empty. the LSS Module.
Controls are prevented in the
1. Ensure that the LSS Module is powered. The LSS Module’s LED will be lit or flash if
same manner as when overthe module is powered. If not, ensure that approximately 12V is present between J1loaded.
1 and J1-2 on the LSS Module (J1-1 is positive). Trace the Ignition and Ground supply wires into the Host Control System’s wiring harness using the wiring diagram to
locate the difficulty.
2. Plug a JLG Analyzer into the LSS Module’s connection and ensure that the Host
Control System is powered-up. When HELP:PRESS ENTER is displayed, press the
ENTER key on the Analyzer. If “EVERYTHING OK” is displayed, it is probable that
the Overload Signal from the LSS Module is not reaching the Host Control System.
This signal is present on LSS Module’s J1-5 and is approximately 12V normally, and
0V during an overload. This signal eventually reaches the Main Terminal Box to provide the overload signal. Refer to the Wiring Diagram for wire color, number, and terminal information.
3. (LE, MRT and RTS) - If the Analyzer displayed “OVERLOADED” in the previous step,
press the ENTER key again. If “NO CAL” is displayed, the Load Sensing System has
not been properly calibrated. Refer to the Calibration portion of this manual.
4. If another fault is displayed, refer to the portion of this manual that describes Fault
Messages and their causes.
5. The difficulty may be a result of a Measurement Performance issue. Review the Possible Resolutions under those categories.
Controls remain functional at
the Ground Control position
during an overload, or when
simulated by unplugging a
Shear Pin from the LSS Module. The Control at the Platform
Control position are prevented.
3124288
The Host Control System is configured to prevent platform controls only in the event of
overload (as required for EN280 compliance). Alternately, the Host Control System can be
configured to prevent ground and platform controls for country- or customer-specific circumstances.
Plug the JLG Analyzer into the LSS Module’s connection and enter the Access Level 1
password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter
to “CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter
to “CUTOUT ALL” to prevent platform and ground controls in the event of overload.
– JLG Lift –
5-9
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Table 5-5. LSS Module System Interface Connector Power & Digital (J1 - Grey)
Table 5-7. LSS Module Load Cell Connector Pinout (J5,
J6, J7, J8)
Pin
Signal
Description
Pin
1
VBAT
Positive Power Supply from Host Control System
(12-24V)
1
+ Signal
2
Cal Clock
Serial Clock to Sensor’s Integrated Memory
2
GND
Negative Power Supply from Host Control System
(0V)
3
- Excitation
Negative Sensor Supply Voltage (approx. 0V)
3
GND-2
4
+Excitation
Positive Sensor Supply Voltage (approx. 5V)
4
N/C
Unused
5
- Signal
Negative Sensor Output (approx. 2.5V)
5
DO1
Overload Indicator Output (Normal=VBAT / Overload=0V)
6
Cal Data
Serial Data from Sensor’s Integral Memory
6
DO2
Warning Indicator Output (Normal=0V / Overloaded=VBAT for 5 Sec, 0V for 2 Sec)
7
DI3
Unused
8
DI2
Select OVERLD3 Personality Rating (No=0V /
Yes=VBAT)
9
DI1
Select OVERLD2 Personality Rating (No=0V /
Yes=VBAT)
10
GND-2
Connects to GND
11
VBAT-2
Connects to VBAT
12
VBAT-2
Connects to VBAT
Connects to GND
Signal
Description
Positive Sensor Output (approx. 2.5V)
NOTE: Physical connector as viewed looking into the
cable end
Table 5-6. LSS Module System Interface Connector –
Communication (J1 - Black)
Pin
Signal
Description
1
APWR
Pre-Regulated Supply for JLG Analyzer (Analyzer
Pin 1; approx. 12V)
2
TX
3
TRP1
4
CANH-1
RS-232 for JLG Analyzer (Analyzer Pin 3)
120 Ohm CANbus Terminator
CANbus Interface High
5
CANS-1
CANbus Shield Termination (Not same as GND)
6
CANH-2
Connects to CANH-1
7
CANL-2
Connects to CANL-1
8
CANS-2
Connects to CANS-1
9
CANL-1
CANbus Interface Low
10
TRP2
120 Ohm CANbus Terminator
11
RX
RS-232 for JLG Analyzer (Analyzer Pin 2)
12
GND
Ground for JLG Analyzer (Analyzer Pin 4)
5-10
Figure 5-2. LSS Module Load Cell Connector
Pinout (J5, J6, J7, J8)
– JLG Lift –
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SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Figure 5-3. 260MRT Wiring Diagram
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– JLG Lift –
5-11
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Figure 5-4. M3369/M4069 & 3369LE/4069LE Wiring Diagram
5-12
– JLG Lift –
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SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Figure 5-5. 500RTS Wiring Diagram
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– JLG Lift –
5-13
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Figure 5-6. ES Wiring Diagram
5-14
– JLG Lift –
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SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
Figure 5-7. RT Wiring Diagram
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– JLG Lift –
5-15
SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)
NOTES:
5-16
– JLG Lift –
3124288
SECTION 6 - SERVICE - (RS)
SECTION 6. SERVICE - (RS)
6.1
DESCRIPTION (RS)
The platform load sensing system is intended to prevent
machine operation in the event that the platform is overloaded. Machine operation does not return until the platform overload is removed. If the platform load sensing
system is equipped the machine will include 3 additional
components, 2 pressure transducers and 1 angle sensor.
resolution (reference the Troubleshooting section of
this manual). Press ESC to return to the top level
menu.
Platform Load Sensing System Calibration
Procedure (RS)
1. If the Angle Sensor has not been calibrated refer to
the Angle Sensor Calibration Procedure first!
The pressure transducers, which are located at the barrel
end of the lift cylinder, (See Figure 6-1. and Figure 6-2.) are
intended to correlate hydraulic fluid pressure to the load
placed in the platform. The angle sensor, located at the
bottom of the arm stack to the rear of the 10RS, and
underneath the platform at the rear of the machine on the
6RS, (See Figure 6-3.) is intended to correlate machine
elevation with hydraulic fluid pressure as measured by the
pressure transducers.
2. Ensure the batteries are fully charged and the
hydraulic fluid level is acceptable.
3. Park the vehicle on a level surface. The platform
should be fully stowed and level within +/- 0.5
degrees (both directions).
4. Ensure the temperature is greater than 32 degrees
Fahrenheit.
5. Place weight corresponding to 110% of the
machines rated load in the center of the platform.
Secure the weight to the platform. See the chart
below to determine the correct weight for calibration
on each machine.
NOTE: JLG specifications require that this procedure be
performed every 500 machine hours or 6 months,
whichever occurs first. Calibrating the platform load
sensing system regularly is essential to safe machine
operation. Continuing to operate a machine without
calibrating at the recommended specifications could
compromise machine stability resulting in a
machine tip-over.
6.2
CALIBRATION (RS)
The load sensing system cannot be calibrated without first
calibrating the machines Angle Sensor. The load sensing
system will not measure load at or below the elevation
switch trip point.
Table 6-1. Platform Calibration Weight - RS
MACHINE
CALIBRATION WEIGHT
1932RS/6RS
550 lbs. (250 Kg)
3248RS/10RS
775 lbs. (352 Kg)
6. Remove the orange panel on the ground control key
switch side of the machine.
7. Disconnect the MDI display and connect the JLG
Analyzer.
Angle Sensor Calibration Procedure (RS)
1. Ensure the batteries are fully charged and the
hydraulic fluid level is acceptable.
8. Navigate to the ACCESS LEVEL menu on the Analyzer and enter the Access Level 1 code.
2. Park the vehicle on a level surface. The platform
should be fully stowed and level within +/- 0.5
degrees (both directions).
9. Execute a Load Calibration via the JLG Analyzer.
Proceed to the Analyzer's CALIBRATION top level
menu and press ENTER. Navigate to the LOAD submenu and press ENTER. Press ESC to abort a calibration or ENTER to calibrate. If successful the
Analyzer will display COMPLETE!. If unsuccessful, a
message will be displayed that will help lead to a
resolution (reference the Troubleshooting section of
this manual). Press ESC to return to the top level
menu.
3. Remove the orange panel on the ground control key
switch side of the machine.
4. Disconnect the MDI display and connect the JLG
Analyzer.
5. Navigate to the ACCESS LEVEL menu on the Analyzer and enter the Access Level 1 code.
6. Execute a Angle Calibration via the JLG Analyzer.
Proceed to the Analyzer's CALIBRATION top level
menu and press ENTER. Navigate to the ANGLE
submenu and press ENTER. Press ESC to abort a
calibration or ENTER to calibrate. If successful the
Analyzer will display COMPLETE!. If unsuccessful, a
message will be displayed that will help lead to a
3124288
– JLG Lift –
6-1
SECTION 6 - SERVICE - (RS)
6.3
TESTING AND EVALUATION (RS)
Refer to the troubleshooting section of this manual if the
Load Sensing System fails to meet these guidelines.
1. Park the vehicle on a level surface. The platform
should be fully stowed and level within +/- 0.5
degrees (both directions).
2. Ensure Pressure Transducers work appropriately.
Proceed to the DIAGNOSTICS, LOAD submenu and
ensure that PRES1 and PRES2 are within 10 PSI of 0
with the platform stowed. Engage lift up from the
ground panel and ensure that the PRES1 and
PRES2 readings begin to increase as the machine
elevates.
3. Ensure the Angle Sensor works appropriately. Proceed to the DIAGNOSTICS, ANGLE submenu and
ensure that ANGLE, ANGLE increases as the
machine elevates and decreases as the machine
descends.
4. Confirm Host Control System Warnings and Interlocks and Load Sensing System Performance with
Calibrated Weights. Using the vehicle’s key switch
select ground mode and power-up. Ensure that all
controls are functional and the Load Sensing Systems Visual and Audible Warnings are not active.
Engage lift up from the Ground Panel until the platform reaches maximum elevation, and then engage
6-2
– JLG Lift –
lift down from the Ground Panel until the platform
becomes stowed. Ensure that the Overload Visual
and Audible alarm did not activate at either control
position during this procedure. Ensure that the Load
Sensing System activates with 120% rated load
placed in the center of the platform. With the platform stowed engage lift up with 120% rated load
placed in the center of the platform ensuring that the
Load Sensing System activates within the ranges
listed in the following table. Ensure that the DIAGNOSTICS, LOAD, OVERLOADED submenu reads
YES. The Overload Visual Warning should flash at
the selected control position and the Audible Warning should sound for 5 seconds On and 2 seconds
Off. With the machine On all platform movement
should be prevented. Cycle the Ground Panel Emergency Stop button. The Overload Visual and Audible
Warning should continue. Pull the manual descent
lever until the platform becomes stowed. The Overload Visual and Audible Warnings should cease and
all normal control function should return.
Table 6-2. System Activation Height - RS
MACHINE
SYSTEM ACTIVATION HEIGHT
1932RS/6RS
4.92 - 8.20 ft. (1.5 - 2.5m)
3248RS/10RS
8.20 - 11.48 ft. (2.5 - 3.5m)
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SECTION 6 - SERVICE - (RS)
6.4
LSS TROUBLESHOOTING (RS)
The following tables are furnished to provide possible resolutions for common difficulties.
Table 6-3. LSS Troubleshooting - RS
PROBLEM
POSSIBLE RESOLUTION
JLG Analyzer displays "MAX NOT IN
RANGE" after the step "LIFT TO MAX"
during Angle Calibration
The Angle Sensor’s upper limit is not acceptable. The Angle Sensor’s reading
must fall within +/- 35 counts of 210 counts when the platform is at maximum elevation.
1. Check the Angle Sensor to ensure that it is installed properly and that no
debris has become lodged around the Angle Sensor lever arm.
2. Ensure that the lever arm is installed properly and is not damaged.
JLG Analyzer displays "MAXANGLE
TO HIGH" after the step "LIFT TO MAX"
during Angle Calibration
The Angle Sensor's reading when the platform is at maximum elevation was
greater than 245 counts. The Angle Sensor's reading when the platform is at maximum elevation must be a number less than or equal to 245 counts.
1. Check the Angle Sensor to ensure that it is installed properly and that no
debris has become lodged around the Angle Sensor lever arm.
2. Ensure that the lever arm is installed properly and is not damaged.
JLG Analyzer displays "LOW NOT IN
RANGE" after the step "LOWER TO
STOWED" during Angle Calibration
The Angle Sensors lower limit is not acceptable. The Angle Sensor’s reading
must fall within +/- 35 counts of 40 counts when the platform is stowed.
1. Check the Angle Sensor to ensure that it is installed properly and that no
debris has become lodged around the Angle Sensor lever arm.
2. Ensure that the lever arm is installed properly and is not damaged.
JLG Analyzer displays "MINANGLE
TOO LOW" after the step "LOWER TO
STOWED" during Angle Calibration
The Angle Sensor's reading when the platform is stowed was less than 5 counts.
The Angle Sensor's reading when the platform is stowed must be a number
greater than or equal to 5 counts.
1. Check the Angle Sensor to ensure that it is installed properly and that no
debris has become lodged around the Angle Sensor lever arm.
2. Ensure that the lever arm is installed properly and is not damaged.
JLG Analyzer displays "CAL FAIL!" at
any time during the ANGLE calibration.
The technician has pressed ESC on the Analyzer during the calibration routine or
the Angle Sensor’s Range with the platform stowed to the platform at maximum
elevation was not acceptable.
1. ESC was accidentally pressed during the Calibration procedure. The previously calibrated values will not be lost. Attempt ANGLE calibration again.
2. Check the Angle Sensor to ensure that it is installed properly and that no
debris has become lodged around the Angle Sensor lever arm.
3. Ensure that the lever arm is installed properly and is not damaged.
JLG Analyzer displays "INVALID
RANGE" after the step "LOWER TO
STOWED"
The sensors range from stowed to maximum height was not acceptable.
JLG Analyzer displays "NOT IN GND
MODE" when attempting to perform a
LOAD Calibration
The machine is not in Ground Mode.
JLG Analyzer displays "CAL ANGLE"
when attempting to perform a LOAD
Calibration.
The Angle Sensor has not been calibrated.
3124288
1. Check to ensure that the Angle sensor is mounted properly.
2. Ensure that the angle sensors lever arm is still functioning properly and is
not broken.
1. Re-attempt LOAD Calibration after setting the key switch to the Ground
Control position.
1. The Angle Sensor must be calibrated before a LOAD calibration can occur.
Enter the CALIBRATIONS menu and perform an ANGLE calibration.
– JLG Lift –
6-3
SECTION 6 - SERVICE - (RS)
Table 6-3. LSS Troubleshooting - RS (Continued)
PROBLEM
POSSIBLE RESOLUTION
JLG Analyzer displays "MOTION
STOPPED" after the LOAD calibration
steps "LIFT TO MAX ELEV" or "LOWER
TO STOWED".
The platform stopped moving during LOAD calibration.
JLG Analyzer displays "CAL FAIL!"
when attempting to perform a LOAD
Calibration.
The technician has pressed ESC on the Analyzer during the calibration routine.
The Visual and Audible Overload
Warnings fail to sound when platform
is loaded beyond rated load. Controls
remain functional at Ground and Platform Control Positions.
The Load Sensing System is failing to detect that an overload condition exists or
the Load Sensing system has not been enabled.
1. The technician let go of the lift up switch before the machine reached maximum elevation during "CAL LOAD: LIFT TO MAX ELEV" or the technician
let go of the lift down switch before the machine became stowed after the
"CAL LOAD: LOWER TO STOWED" step. Re-attempt LOAD calibration
making sure not to disengage the lift up and lift down switch during these
steps.
1. ESC was accidentally pressed during the Calibration procedure. The previously calibrated values will not be lost. Attempt LOAD calibration again.
1. The Load Sensing System must be enabled within the Host Control System. Connect the JLG Analyzer and enter the Access Level 1 Password
(33271). Navigate to MACHINE SETUP, LOAD submenu. The selection
"CUTOUT PLT" should be displayed for European Community Compliance
(platform controls prevented during overload, ground controls remain
operational). In country- or customer-specific circumstances, the selection
"CUTOUT ALL" is used (platform and ground controls prevented during an
overload).
2. The Load Sensing System requires re-calibration. If the Load Sensing System fails to detect an Overload with 120% load placed in the platform perform an ANGLE calibration followed by a LOAD calibration as specified by
the Calibration procedures listed in this document.
3. If a fault is displayed, refer to the portion of this manual that describes
Fault Messages and their causes.
The Visual and Audible Overload
Warnings sound even when platform
is empty. Controls are prevented in the
same manner as when overloaded.
The Load Sensing System has not been calibrated or is experiencing a measurement performance difficulty.
1. The machine is assumed to be overloaded until the Load Sensing System
has been calibrated. Navigate to the CALIBRATIONS menu and perform
an ANGLE calibration followed by a LOAD calibration.
2. The Load Sensing System requires re-calibration. If the Load Sensing System falsely detects an Overload with less than rated load placed in the
platform perform an ANGLE calibration followed by a LOAD calibration as
specified by the Calibration procedures portion of this manual.
3. If a fault is displayed, refer to the portion of this manual that describes
Fault Messages and their causes.
Controls remain functional at the
Ground Control position during an
overload.
The Control at the Platform Control
positions are prevented.
6-4
The Host Control System is configured to prevent platform controls only in the
event of overload. Alternately, the Host Control System can be configured to prevent ground and platform controls for country- or customer-specific circumstances.
1. Plug the JLG Analyzer in and enter the Access Level 1 password (33271).
Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to
"CUTOUT PLT" to prevent platform controls in the event of overload. Set
this parameter to "CUTOUT ALL" to prevent platform and ground controls
in the event of overload.
– JLG Lift –
3124288
SECTION 6 - SERVICE - (RS)
6.5
LSS COMPONENT REMOVAL/
INSTALLATION (RS)
3
Pressure Transducer Removal (RS)
(See Figure 6-1. and Figure 6-2.)
Use the following procedure to safely remove and repair
the pressure transducers on the lift cylinder.
2
1. Ensure that the key switch is set to ground mode.
2. Engage lift up from the ground panel until the platform has elevated high enough to engage the lift cylinder safety prop.
3. Engage the platform safety prop.
4. Lower the platform on to the safety prop and continue to engage lift down for 1 second after the platform makes contact with the safety prop.
1
5. Disconnect power at the batteries.
6. Carefully disconnect the electrical connectors on
each sensor.
Figure 6-1. LSS Pressure Transducer Location 1932RS/6RS
7. Remove each pressure transducer.
1. Ports On Barrel of Cylinder
2. Pressure Transducers
Pressure Transducer Installation (RS)
1. Insert new pressure transducer and tighten.
3. Harness Connectors
2. Reconnect each pressure transducers electrical
connector.
3. Reconnect power at the batteries.
4. Turn machine on and engage lift up from the ground
panel so that the safety prop can be disengaged.
5. Lower the platform to the stowed position.
6. This completes pressure transducer repair.
1
2
3
Figure 6-2. LSS Pressure Transducer Location 3248RS/10RS
1. Ports On Bottom of Cylinder
2. Pressure Transducers
3124288
– JLG Lift –
3. Harness Connectors
6-5
SECTION 6 - SERVICE - (RS)
10RS Angle Sensor Removal (RS)
6RS Angle Sensor Removal (RS)
(See Figure 6-1. and Figure 6-2.)
1. Ensure that the key switch is set to ground mode.
1. Ensure that the platform is stowed and the machine
is on level ground.
2. Disconnect power at the batteries.
2. Engage lift up from the ground panel until the platform has elevated high enough to engage the lift cylinder safety prop.
3. Locate the Angle Sensor at the back of the machine.
3. Engage the platform safety prop.
4. Disconnect the Angle Sensor’s electrical connection.
4. Lower the platform on to the safety prop and continue to engage lift down for 1 second after the platform makes contact with the safety prop.
5. Remove the Angle Sensor.
5. Disconnect power at the batteries.
10RS Angle Sensor Installation (RS)
6. Disconnect the Angle Sensor’s electrical connection.
1. Install the Angle Sensor with the mounting hardware.
2. Reconnect the Angle Sensor’s electrical connector.
3. Reconnect power at the batteries.
7. Remove the Angle Sensor.
6RS Angle Sensor Installation (RS)
1. Install the Angle Sensor with the mounting hardware.
4. Recalibrate the machine’s Angle Sensor.
5. Recalibrate the machine’s Load Sensing System.
2. Reconnect the Angle Sensor’s electrical connector.
3. Reconnect power at the batteries.
4. Turn machine on and engage lift up from the ground
panel so that the safety prop can be disengaged.
5. Lower the platform to the stowed position.
6. Recalibrate the machine’s Angle Sensor.
7. Recalibrate the machine’s Load Sensing System.
1932RS/6RS
3248RS/10RS
1. Platform Gate
2. LSS Scissor Arm Angle Sensor (rear plate shown cutaway)
3. Platform Entry Ladder
1. Elevation Limit Switch Location
2. LSS Scissor Arm Angle Switch (scissor arms shown cutaway)
3. Platform Entry Ladder
Figure 6-3. LSS - Scissor Arm Angle Sensor - (RS)
6-6
– JLG Lift –
3124288
SECTION 6 - SERVICE - (RS)
LSS Connector Pin Assignments (RS)
Table 6-4. Connections to Host Control System
(J1-Black) (RS)
PIN
SIGNAL
DESCRIPTION
1
PRES1
Pressure Transducer 1 Input (0-5V)
2
PRES2
Pressure Transducer 2 Input (0-5V)
16
PPRES
Pressure Transducers Analog Reference (0-5V)
17
NPRES
Pressure Transducers Negative Reference
Table 6-6. Angle Sensor Connector Pinout (RS)
PIN
SIGNAL
1
GND
Angle Sensor Ground
2
PWR
Angle Sensor Power (10 - 30V)
3
NC
No Connect
4
NC
No Connect
5
CANH
Angle Sensor CANbus High
6
CANL
Angle Sensor CANbus Low
Table 6-5. Connections to Host Control System
(J2-Blue) (RS)
PIN
SIGNAL
5
CANL
CANbus Low
6
CANH
CANbus High
15
CANS
CANbus Shield
22
NOVL
Nagative for Overload Lamp (Low-Side Driver)
3124288
DESCRIPTION
DESCRIPTION
Table 6-7. Pressure Transducer Connector Pinout
(RS)
PIN
SIGNAL
A
PWR
Pressure Transducer Power (+5V)
B
GND
Pressure Transducer Ground
C
SIG
Pressure Transducer Analog Output (0 - 5V)
– JLG Lift –
DESCRIPTION
6-7
GRN
RED X25-7
(splice block)
BLK S34 (B–)
CANH
CANL
PWR
GND
WHT 61 GND
PRES2
GND
+5V
WHT 60 5V SEN
WHT 59 PRES2
WHT 58 PRES1
PRES1
GND
+5V
PLATFORM CONTROL
OVERLOAD LAMP
TRANSDUCER-2
A B C
GRN
TRANSDUCER-1
PRES 2
PRES 1
1 2 16 17
PPRES
NC
YEL
S03
NPRES
LB89 –
SHIELD
A B C
CANH
CANL
5 6 15 22
J2 - BLUE
NOVL
CANS
YEL
S04
J1 - BLACK
HOST CONTROL MODULE (ZAPI)
WHT 42 OVERLOAD LAMP
SHIELD
LB89 +
ANGLE SENSOR
GRN
(PLATFORM
CABLE)
X12-19
X10-19
WHT 42-2 OVLD LMP
1 2 3 4 5
WHT 42-1 OVLD LMP
YEL 3-15 IGN
X28-19
X11-19
– LB24
YEL 3-16 IGN
X48-7
+ LB24
X25-4
GROUND CONTROL
OVERLOAD LAMP
SECTION 6 - SERVICE - (RS)
Figure 6-4. LSS - Electrical Component Schematic - (RS)
6-8
– JLG Lift –
3124288
SECTION 7. PARTS
TABLE OF CONTENTS
FIGURE
7-1
7-2
7-3
7-4
7-5
3124288
DESCRIPTION
LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE) . . . .
LOAD SENSING SYSTEM INSTALLATION (500RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING SYSTEM INSTALLATION (1930ES/2030ES/2630ES/2646ES/3246ES) . . . .
LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/3248RS) . . . . . . . . . . . . . . .
LOAD SENSING SYSTEM INSTALLATION (34694RT/4394RT) . . . . . . . . . . . . . . . . . . . . . . . .
– JLG Lift –
PAGE
7-2
7-6
7-8
7-12
7-14
7-1
FIGURE 7-1.
LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069
& 3369LE/4069LE)
LEFT FRONT
PLATFORM
SLIDE BLOCK
18
LEFT REAR
PLATFORM
SLIDE BLOCK
29
29
20
20A
29
18
7
RIGHT FRONT
PLATFORM
SLIDE BLOCK
20B
LE MACHINES
34B
LE MACHINES
7
20A
20
20
20B
29
LE MACHINES
20A
29
7
34B
LE MACHINES
RIGHT REAR
PLATFORM
SLIDE BLOCK
18
20A
29
20
29
18
34
29
7
34A LE MACHINES
20B MRT MACHINES
20
TO
ANALYZER
32B
32
10
34
4
20B
15
32A 33A
20
33
159
PLATFORM
CONTROL
BOX
INDICATOR
LIGHT
33D
GROUND
CONTROL
BOX
INDICATOR
LIGHT
TO
LOAD
SENSE
POWER
SUPPLY
33C
33B
7-2
– JLG Lift –
3124288
.
FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE)
FIG & ITEM #
PART NUMBER
0272964
0272965
0272930
0272931
1 to 3
4
5 to 6
7
0641405
0641415
Not Used
3931648
4032022
11 to 14
15
16 to 17
18
19
20
20A
20B
21 to 28
29
30 to 31
32
32A
32B
REV.
Ref.
Ref.
Ref.
Ref.
Ref.
F
E
I
I
Bolt Options:
Prior to S/N 0200120066
S/N 0200120066 to Present
3
Bolt Options:
260MRT:
Bolt 3/8”-16NC x 4 1/2” (Prior to S/N 0200124148)
Bolt (Metric) M10 x 120mm (S/N 0200124148 to Present)
E/M3369/4069LE:
Capscrew 3/8”-16NC x 3” (Prior to S/N 0200124146)
Capscrew (Metric) M10 x 90mm (S/N 0200124146 to
Present)
4
Module, Load Sensing Options:
Prior to S/N 0200120066
S/N 0200120066 to Present
1
Locknut 1/4”-20NC
3
Locknut Options:
Locknut 3/8”-16NC (Prior to S/N 0200124146)
Locknut (Metric) M10 (S/N 0200124146 to Present)
4
Pin, Load Management (Includes Harness)
Connector, Strain Relief
Plug, Male 6 Position
Socket, Female
4
1
1
6
Flatwasher 3/8”
8
Module to Analyzer Harness
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Connector, Female 4 Position
Pin, Male
Main Load Sensing Harness
260MRT (Prior to S/N 0200193881)
E/M3369/4069LE (Prior to S/N 0200152398)
1
1
4
8
1
1
4
1
Not Used
1600350
1600387
Not Used
3311405
Not Used
3311605
3291005
Not Used
3422938
Not Available
Not Available
Not Available
Not Used
4751600
Not Used
4922904
4460836
4460465
4460466
0840055
4460761
4460294
33
4922915
4922903
3124288
QTY.
Not Used
0641636
0701029
8 to 9
10
DESCRIPTION
LOAD SENSING SYSTEM INSTALLATION
260MRT (Platform without D-Rings)
260MRT (Platform with D-Rings)
E/M3369/4069LE (Platform without D-Rings)
E/M3369/4069LE (Platform with D-Rings)
– JLG Lift –
E
B
A
B
7-3
FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE)
FIG & ITEM #
PART NUMBER
33A
4460836
4460465
4460466
0840055
4460897
4460464
4460932
4460464
4460049
1061020
Not Available
Not Available
Not Available
Not Available
33B
33C
33D
34
34A
34B
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Connector, Female 2 Position
Pin, Male
Connector, Female 4 Position
Pin, Male
Connector, Strain Relief
Cable, Extension (E/M3369/4069LE Only)
Plug, Male 6 Position
Socket, Female
Connector, Female 6 Position
Pin, Male
1001110710
0275525
0275526
SCISSOR ARMS INSTALLATIONS WITH LSS (LE ONLY)
260MRT
3369LE
4069LE
4922915
4922903
Load Sensing Harness Options:
260MRT (S/N 0200193881 to Present)
E/M3369/4069LE (S/N 0200152398 to Present)
159
7-4
DESCRIPTION
– JLG Lift –
QTY.
1
4
8
1
1
2
1
4
1
2
1
6
1
6
Ref.
Ref.
Ref.
Ref.
REV.
B
A
A
A
A
B
3124288
FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE)
FIG & ITEM #
3124288
PART NUMBER
DESCRIPTION
– JLG Lift –
QTY.
REV.
7-5
FIGURE 7-2. LOAD SENSING SYSTEM INSTALLATION (500RTS)
7-6
– JLG Lift –
3124288
.
FIGURE 7-2. LOAD SENSING SYSTEM INSTALLATION (500RTS)
FIG & ITEM #
PART NUMBER
0272973
0272975
1 to 2
3
4 to 5
6
7 to 9
10
11
12
13
14
15
15A
15B
16 to 19
20
21 to 24
25
26
26A
26B
27
27A
28
28A
28B
3124288
DESCRIPTION
LOAD SENSING SYSTEM INSTALLATION (CE SPEC)
500RTS with Standard Deck
500RTS with Mega Deck
QTY.
REV.
Ref.
Ref.
Ref.
E
E
Not Used
0641406
0641416
Not Used
0641668
Not Used
1600350
1600387
Not Used
3311405
3311605
Not Used
3422939
Not Available
Not Available
Not Available
Not Used
4240033
Not Used
4751600
4922904
4460836
4460465
4460466
0840055
4460761
4460294
4922911
4460933
4460465
4460466
0840055
1061021
Not Available
Not Available
Not Available
Not Available
Bolt Options:
Bolt 1/4”-20NC x 3/4” (Prior to S/N 0200120099)
Bolt 1/4”-20NC x 2” (S/N 0200120099 to Present)
3
Bolt 3/8”-16NC x 8 1/2”
4
Module, Load Sensing Options:
Prior to S/N 0200120099
S/N 0200120099 to Present
1
Locknut 1/4”-20NC
Locknut 3/8”-16NC
3
4
Pin, Load Management (Includes Harness)
Connector, Strain Relief
Plug, Male 6 Position
Socket, Female
4
1
1
6
Tie-Strap
4
Flatwasher 3/8” Wide
Module to Analyzer Harness
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Connector, Female 4 Position
Pin, Male
Main Load Sensing Harness
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Cable, Extension
Plug, Male 6 Position
Socket, Female
Connector, Female 6 Position
Pin, Male
8
1
1
4
8
1
1
4
1
1
4
8
1
2
1
6
1
6
– JLG Lift –
D
B
B
B
7-7
FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/
2646ES/3246ES)
LEFT FRONT
PLATFORM
SLIDE BLOCK
4
8
7
LEFT REAR
PLATFORM
SLIDE BLOCK
18
RIGHT FRONT
PLATFORM
SLIDE BLOCK
8A
7
4
8A
8
8
18
RIGHT REAR
PLATFORM
SLIDE BLOCK
8A
5
7
12
8A
8
18
7
18
13
6
5
8B
10
8
14
8
8
8B
8
12
17
16
11B 11C
13
11
11D
TO
LOAD
SENSE
POWER
SUPPLY
7-8
– JLG Lift –
11A
TO
ANALYZER
3124288
.
FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES)
FIG & ITEM #
PART NUMBER
0272836
0275029
0272837
0274992
0272838
0274931
1 to 3
4
5
0701026
0701027
6
1600366
1600387
9
10
11
1600366
1600387
3291005
3422938
Not Available
Not Available
Not Available
Not Used
4191707
4922908
4923228
11A
3124288
QTY.
REV.
Ref.
Ref.
Ref.
M
Ref.
D
Ref.
Ref.
N
Ref.
C
Ref.
Ref.
M
Ref.
B
Not Used
0701022
0701024
7
8
8A
8B
DESCRIPTION
LOAD SENSING SYSTEM INSTALLATION (CE SPEC)
1930ES:
USA Built Machines Prior to S/N 0200150266 & Belgium
Built Machines Prior to S/N 1200007882
USA Built Machines S/N 0200150266 to Present & Belgium Built Machines S/N 1200007882 to Present
2030ES/2630ES:
USA Built Machines Prior to S/N 0200152825 & Belgium
Built Machines Prior to S/N 1200008481
USA Built Machines S/N 0200152825 to Present & Belgium Built Machines S/N 1200008481 to Present
2646ES/3246ES:
USA Built Machines Prior to S/N 0200151610 & Belgium
Built Machines Prior to S/N 1200008265
USA Built Machines S/N 0200151610 to Present & Belgium Built Machines S/N 1200008265 to Present
4922908
4923228
4460761
4460294
Bolt Options:
Bolt M10 x 70mm (1930ES)
Bolt M10 x 80mm (2030ES/2630ES/2646ES/3246ES)
Bolt Options:
Bolt M10 x 90mm (1930ES)
Bolt M10 x 100mm (2030ES/2630ES/2646ES/3246ES)
Module, Load Sensing Options:
USA Built Machines:
Prior to S/N 0200120069
S/N 0200120069 to Present
Belgium Built Machines:
Prior to S/N 1200001581
S/N 1200001581 to Present
Locknut M10
Pin, Load Management (Includes Harness)
Connector, Strain Relief
Plug, Male 6 Position
Socket, Female
Screw M6 x 16mm
Module to Analyzer Harness Options:
USA Built Machines:
Prior to S/N 0200150266
S/N 0200150266 to Present
Belgium Built Machines:
Prior to S/N 1200007882
S/N 1200007882 to Present
Connector, Female 4 Position
Pin, Male
– JLG Lift –
2
2
1
4
4
1
1
6
E
2
1
D
B
D
B
1
4
7-9
FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES)
FIG & ITEM #
PART NUMBER
11B
4460836
4460465
4460466
0840055
4460836
4460465
4460466
0840055
3990110
4460899
4460464
1320318
1380158
11C
11D
12
13
14
3680055
Use 4340931
4340931
3680055
Use 4340931
15
16
4340931
4240033
0700608
0700617
17
18
19
7-10
0700608
0700617
3290606
4812000
0100048
DESCRIPTION
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Diode, Voltage Suppressor
Connector, Female 6 Position
Pin, Male
Clamp
Clip
Plate, Cable Reel Options:
USA Built Machines:
Prior to S/N 0200113763
S/N 0200113763 to S/N 0200121287 (was p/n
3200456)
S/N 0200121287 to Present
Belgium Built Machines:
Prior to S/N 1200002229
S/N 1200002229 to S/N 1200001914 (was p/n
3200456)
S/N 1200001914 to Present
Tie-Strap (Not Shown)
Bolt Options:
USA Built Machines:
Bolt M6 x 16mm (Prior to S/N 0200120069)
Bolt M6 x 45mm (S/N 0200120069 to Present)
Belgium Built Machines:
Bolt M6 x 16mm (Prior to S/N 1200001581)
Bolt M6 x 45mm (S/N 1200001581 to Present)
Nut M6
Flatwasher 10mm
Grease, Dielectric (Not Shown)
– JLG Lift –
QTY.
REV.
1
8
4
1
1
3
10
1
1
1
5
3
3
1
1
3
3
4
A/R
3124288
FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES)
FIG & ITEM #
3124288
PART NUMBER
DESCRIPTION
– JLG Lift –
QTY.
REV.
7-11
FIGURE 7-4. LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/
3248RS)
35
10S/3248RS
6RS/1932RS
35
45A
45B
40
45
43
6RS/1932RS (SHOWN)
10RS/3248RS (NOT SHOWN - TYPICAL)
7-12
– JLG Lift –
3124288
.
FIGURE 7-4. LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/3248RS)
FIG & ITEM #
PART NUMBER
1001147250
1001147251
1 to 5
6
7 to 34
35
36 to 39
40
41 to 42
43
44
45
3124288
Not Used
3290607
Not Used
1001147340
See Note
Not Used
3290405
Not Used
4031512
Not Used
1001151800
70004167
70004168
See Note
DESCRIPTION
LOAD SENSING SYSTEM INSTALLATION (CE SPEC)
6RS/1932RS
10RS/3248RS
QTY.
REV.
Ref.
Ref.
Ref.
C
C
Locknut M6
1
Sensor, Pressure Transducer
Harness (Note: Refer to Model Specific Parts Manual)
2
1
Locknut M4
2
Capscrew m4 x 40mm
2
Sensor, Angle
Arm
Pin, Dowel
Harness (Note: Refer to Model Specific Parts Manual)
1
1
1
1
– JLG Lift –
7-13
FIGURE 7-5. LOAD SENSING SYSTEM INSTALLATION (3394RT/4394RT)
LEFT FRONT
PLATFORM
SLIDE BLOCK
3
5
4
LEFT REAR
PLATFORM
SLIDE BLOCK
5A
4
RIGHT FRONT
PLATFORM
SLIDE BLOCK
5
5A
5B
17B
5
5B
3
3
5
17B
RIGHT REAR
PLATFORM
SLIDE BLOCK
5A
4
5A
4
5
3
MODULE
RIGHT FRONT
OF
MACHINE
12
11
13
22
5
17
17A
22
17
10
16A
5B
5
16B
5B
15
14B 14E
16
16B
14
16
PLATFORM
MODULE
14D
14C
7-14
TO
CLADDER
ACCESSORY
14A
– JLG Lift –
TO
ANALYZER
3124288
.
FIGURE 7-5. LOAD SENSING SYSTEM INSTALLATION (3394RT/4394RT)
FIG & ITEM #
PART NUMBER
0271683
1 to 2
3
4
11
12
13
14
14A
14B
14C
14D
14E
15
16
16A
16B
17
17A
3124288
QTY.
REV.
Ref.
Ref.
G
Not Used
0641660
0701037
5
5A
5B
6 to 8
9
10
DESCRIPTION
LOAD SENSING SYSTEM INSTALLATION (CE SPEC)
3394RT/4394RT
3311605
3311605
3422938
Not Available
Not Available
Not Used
0100011
1600350
1600387
0641405
0902837
4751400
4922882
4460761
4460294
4460836
4460465
4460466
0840055
4460930
4460465
4460466
0840058
4460931
4460464
4460466
0840058
4460933
4460465
4460466
0840055
3311405
1061020
Not Available
Not Available
Not Available
Not Available
1061021
Not Available
Not Available
Bolt Options:
Bolt 3/8”-16NC x 7 1/2” (Prior to S/N 0200124146)
Bolt (Metric) M10 x 200mm (S/N 0200124146 to Present)
Locknut Options:
Locknut 3/8”-16NC (Prior to S/N 0200124146)
Locknut (Metric) M10 (S/N 0200124146 to Present)
Pin, Load Management (Includes Harness)
Connector, Strain Relief
Plug, Male 6 Position
Loctite #242 (Not Shown)
Module, Load Sensing
Prior to S/N 0200119881
S/N 0200119881 to Present
Bolt 1/4”-20NC x 5/8”
Bracket, Module Mounting
Flatwasher 1/4”
Module to Analyzer Harness
Connector, Female 4 Position
Pin, Male
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Plug, Male 8 Position
Socket, Female
Seal, Plug
Boot
Connector, Female 8 Position
Pin, Male
Seal, Plug
Boot
Plug, Male 12 Position
Socket, Female
Seal, Plug
Boot
Locknut 1/4”-20NC
Cable, Extension (1 Meter)
Plug, Male 6 Position
Socket, Female
Connector, Female 6 Position
Pin, Male
Cable, Extension (3 Meter)
Plug, Male 6 Position
Socket, Female
– JLG Lift –
4
4
4
1
1
E
A/R
1
3
1
3
1
1
4
1
8
4
1
1
5
3
1
1
5
3
1
1
2
10
1
3
2
1
6
1
6
2
1
6
C
B
B
7-15
FIGURE 7-5. LOAD SENSING SYSTEM INSTALLATION (3394RT/4394RT) (CONTINUED)
FIG & ITEM #
PART NUMBER
17B
Not Available
Not Available
Not Used
4240033
Not Used
18 to 19
20
21
22
0641405
0641415
7-16
DESCRIPTION
Connector, Female 6 Position
Pin, Male
Tie-Strap (Not Shown)
Bolt Options:
Bolt 1/4”-20NC x 5/8” (Prior to S/N 0200119881)
Bolt 1/4”-20NC x 1 7/8” (S/N 0200119881 to Present)
– JLG Lift –
QTY.
REV.
1
6
A/R
3
3124288
3124288
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+61 2 65 811111
+61 2 65 813058
+55 19 3295 1025
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45
+55 19 3295 0407
JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
(852) 2639 5783
JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
+44 (0)161 654 1000
+44 (0)161 654 1001
JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy
+39 029 359 5210
+39 029 359 5845
JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France
+33 (0)5 53 88 31 70
+33 (0)5 53 88 31 79
Oshkosh-JLG Singapore
Technology Equipment Pte
Ltd
29 Tuas Ave 4,
Jurong Industrial Estate
Singapore, 639379
+65-6591 9030
(852) 2639 5797
+65-6591 9031
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain
+34 93 772 4700
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0)850 659 500
+46 (0)850 659 534
+34 93 771 1762
www.jlg.com

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