JLG FS80 User Manual
Operation & Safety, Service &
Maintenance & Illustrated Parts
Manual Supplement
JLG
LOAD
SENSING
SYSTEM
Boom Lift Products
P/N
3124287
July 24, 2013
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
AGENERAL
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.
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.
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.
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.
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.
B 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.
CMAINTENANCE
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.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM 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.
• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
3124287 – JLG Lift – A-1
INTRODUCTION
REVISON LOG
Original Issue - March 25, 2003
Revised - April 10, 2003
Revised - June 6, 2003
Revised - March 1, 2004
Revised - October 15, 2004
Revised - November 1, 2004
Revised - July 15, 2006
Revised - June 4, 2010
Revised - March 31, 2011
Revised - March 1, 2012
Revised - August 11, 2012
Revised - January 23, 2013
Revised - July 24, 2013
A-2 – JLG Lift – 3124287
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - OPERATION
1.1 Introduction & Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Connecting the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Changing Access Level Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 Viewing & Adjusting Parameters Using the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.6 Help Menu & Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.8 Personalities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.9 Machine Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.10 Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.11 JLG Accessories, Including Workstation in the SkyTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
JLG Approved Accessories (Except SkyGlazier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SkyGlazier Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS
2.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS
3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
SECTION 4 - PARTS
3124287 – JLG Lift – i
TABLE OF CONTENTS (Continued)
ii – JLG Lift – 3124287
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. LSS Module Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
2-1. Load Sensing System Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2. Load Sensing System Installation (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2-3. LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2-4. Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
3-1. Load Sensing System Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Load Sensing System Installation (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-3. LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3-4. Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
4-1. Platform Support & Load Sensing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2. Load Sensing Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
3124287 – JLG Lift – iii
TABLE OF CONTENTS (Continued)
iv – JLG Lift – 3124287
TABLE OF CONTENTS
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 LSS Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-2 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3 Personality Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-4 Machine Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
2-1 LSS Troubleshooting Chart - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-2 LSS Troubleshooting Chart - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-3 LSS Troubleshooting Chart - Measurement Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-4 LSS Troubleshooting Chart - Host System Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2-5 LSS Module System Interface Connector - Power & Digital (J1 - Grey) . . . . . . . . . . . . . . . . . . . .2-16
2-6 LSS Module System Interface Connector – Communication (J1 - Black) . . . . . . . . . . . . . . . . . . .2-16
2-7 LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
3-1 LSS Troubleshooting Chart - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-2 LSS Troubleshooting Chart - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-3 LSS Troubleshooting Chart - Measurement Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-4 LSS Troubleshooting Chart - Host System Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-5 LSS Module System Interface Connector - Power & Digital (J1 - Grey) . . . . . . . . . . . . . . . . . . . .3-15
3-6 LSS Module System Interface Connector – Communication (J1 - Black) . . . . . . . . . . . . . . . . . . .3-15
3-7 LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3124287 – JLG Lift – v
TABLE OF CONTENTS (Continued)
vi – JLG Lift – 3124287
SECTION 1. OPERATION
SECTION 1 - OPERATION
NOTE: This manual is intended as a supplement to the indi-
vidual machine’s Operators and Safety Manual.
1.1 INTRODUCTION & OPERATION
NOTE: It is the responsibility of the owner/user/operator/les-
sor/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 via four sensors mounted between the platform and support structure. 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. Operation of the overriding emergency system
(Auxiliary Power Unit).
c. By an authorized person at the ground control
position (optional - ground control functions
may be prevented).
Calibration of the Load Sensing System is performed by
connecting the JLG Analyzer (Analyzer Kit, JLG part no.
2901443), to the Load Sensing System Module. All calibration procedures are menu driven through the use of
the Analyzer. Note that Load Sensing System has an independent Analyzer connection located near the module.
1.2 CONNECTING THE JLG CONTROL SYSTEM ANALYZER
1. Connect the cable supplied with the analyzer, to the
LSS control module located in the platform and connect the remaining end of the cable to the analyzer.
NOTE: Do not confuse the Host Control System and LSS
Module’s Analyzer Connections.
The cable (shown below) has a four pin connector at
each end of the cable; the cable cannot be connected backwards.
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)
e. Platform is removed, replaced, repaired or
shows evidence of impact.
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION
VERIFICATION NOT TO EXCEED 6 MONTHS FROM PREVIOUS
VERIFICATION. REFER TO TESTING & EVALUATION IN SECTION
2.
2. Power up the Control System by turning the key to
the platform or ground position and pulling both
emergency stop buttons on.
3124287 – JLG Lift – 1-1
SECTION 1 - OPERATION
1.3 USING THE ANALYZER
With the machine power on and the analyzer connected
properly, the analyzer will display the following:
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.
The top level menus are as follows:
HELP
DIAGNOSTICS
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS
If you press ENTER at the HELP: PRESS ENTER display
and there are no faults, the Analyzer will display EVERY-
THING OK. In the event of a fault, the Analyzer will display
OVERLOADED.
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.
When a top level menu entry is selected, a new set of
menu items will be displayed as in the following.
DIAGNOSTICS:
PLTLOAD
PLTGROS
OVERLOADED?
CELL 1
CELL 2
CELL 3
CELL 4
SYSTEM
VERSIONS
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. Refer to Figure 1-1., LSS Module Analyzer Flow
Chart for menu layout. You may only view Personality settings while in Access Level 2. Access Level 1 is required to
change Personality settings and calibrate.
The ESC key may be used to leave a sub-menu at any
time.
1.4 CHANGING ACCESS LEVEL USING THE 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 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
1-2 – JLG Lift – 3124287
SECTION 1 - OPERATION
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.
Once the correct password is displayed, press ENTER.
The Access Level should display the following, if the password was entered correctly:
1.5 VIEWING & ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER
Once you have entered Access Level 1 and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, 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.
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.
3124287 – JLG Lift – 1-3
SECTION 1 - OPERATION
1.6 HELP MENU & FAULT CODES
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
Table 1-1. LSS Fault Codes
Help/Logged
Message
Everything OK LED ON The "Normal" Help Message
<MIN CAL Calibration attempt Unsuccessful, Empty Pla tform appears to weigh too little. Improper Model Selection (Machine Setup)
>MAX CAL Calibration attempt Unsuccessful, Empty Pla tform appears to weigh too much. This situation has the same root causes as
BATT TOO LOW 4/1 Incoming Supply Voltage <9.0 Vdc. The control system’s battery voltage is too low due to excess ive electrical load or dis-
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
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
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
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
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
WATCHDOG RST 9/1 Microprocessor’s Watchdog Timer Triggered. This is an indication that the LSS Module has been exposed to excessi ve
EEPROM ERROR 9/2 Memory used to retain Personality/Machine Setup/Calibration has been corrupted an d must be reset by verifying all entries
NO CAL 9/3 Calibration has not been successfully completed. A ne w LSS Module will display this message until properly calibrated.
INTERNAL ERR 9/9 Pin excitation <4.25 V. The sensors may be excessively loading the excitation supply, or the LSS Module may have hard-
Flash
Code
may cause the LSS Module to expect the wrong Empty Platform Weight. This als o 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 throug h sensors).
the "<MIN CAL" Fault Message.
charge.
improper charger operation.
wiring.
wiring.
wiring.
wiring.
electrical noise, or has experienced a hardware difficulty.
and re-calibrating.
ware difficulty.
High Side Driver Error. The load attached to OUT1 or OUT2 is shorted to battery or ground and has been d etected by the LSS
module.
DRDY Interrupt from A/D missing. Thi s may indicate an LSS Module hardware difficulty.
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).
Description of Situation
1-4 – JLG Lift – 3124287
SECTION 1 - OPERATION
1.7 DIAGNOSTIC MENU
The Diagnostic Menu is another troubleshooting tool for
the Load Sensing System. Sensor and status information
is presented in real-time for the technician. Several submenus 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=BOOM LIFT (refer to
Machine Setup Menu).
Table 1-2. Diagnostic Menu Descriptions
Diagnostics Menu
(Displayed on Analyzer 1
CELL 1:
CELL 2:
CELL 3:
CELL 4:
SYSTEM:
st
Line)
Parameter (Displayed
on Analyzer 2
nd
Line)
PLTLOAD +XXXX LBS or Kg Displays (Total Measured Force — Empty Platform Cali-
PLTGROS +XXXX LBS or Kg Displays Total Measured Force (Sum of Cells 1 thru 4
OVERLOADED? Yes / No Displays Current LSS Module Overload Status
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +
INPUT +
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +
INPUT +XX.XXXX mV Displays Cell Reading in mV
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +XX.XXXX mV/V Displays Cell Reading in mV/V
INPUT +
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +
INPUT +
OVLOAD STAT OFF / ON State of Overload Status Digital Output
WARNING OFF / ON St ate of Warning Digital Output
750# CAPACITY OFF / ON St ate of Digital Input #1
1000# CAPACITY OFF / ON St ate of Digital Input #2
BATTERY XX.XX V Displays Current Battery Voltage
EXCITE X.XXXX V Displays Load Cell Excitation Voltage
TEMP +
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.
Press the LEFT and RIGHT Arrow keys to view the displays and select the various sub-menus (CELL 1, CELL 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.
Parameter Value
(Displayed on Analyzer 2
nd
Description
Line)
bration)
LOAD)
XX.XXXX mV/V Displays Cell Reading in mV/V
XX.XXXX mV Displays Cell Reading in mV
XX.XXXX mV/V Displays Cell Reading in mV/V
XX.XXXX mV Displays Cell Reading in mV
XX.XXXX mV/V Displays Cell Reading in mV/V
XX.XXXX mV Displays Cell Reading in mV
XXX.X Deg C Display the Temperature Sensed by the LSS Module
3124287 – JLG Lift – 1-5
SECTION 1 - OPERATION
Table 1-2. Diagnostic Menu Descriptions
Diagnostics Menu
(Displayed on Analyzer 1
VERSIONS:
st
Line)
Parameter (Displayed
nd
on Analyzer 2
Line)
Parameter Value
(Displayed on Analyzer 2
Line)
nd
Description
SOFTWARE PX.XX Displays LSS Module Software Version
HARDWARE X Display LSS Module Hardware Revision
ANALYZER VX.XXXX Displays Analyzer Software Version
1-6 – JLG Lift – 3124287
SECTION 1 - OPERATION
1.8 PERSONALITIES MENU
The Personalities Menu is used to adjust aspects of the
Load Sensing System’s operation. A FACTORY sub-menu
exists for access to unit-specific calibration information
determined during the manufacturing process, should the
need arise.
DO NOT TAMPER WITH THE PARAMETERS WITHIN THE FACTORY SUB-MENU. THESE FACTORS ARE NOT ADJUSTED FOR
NORMAL CALIBRATION. CONSULT THE FACTORY TO RESTORE
THESE PARAMETERS (REFERENCE THE LSS MODULE’S UNIQUE
SERIAL NUMBER).
Table 1-3. Personality Parameters
Submenu
(Displayed on
Analyzer 1st Line)
OVERLD XXXX LBS (or KGS) 550 LBS Displays/adjusts the Overload limit for this AWP*
OVERLD2 XXXX LBS (or KGS) 825 LBS Displays/adjusts an Alternate Overload limit for this AWP*
OVERLD3 XXXX LBS (or KGS) 1100LBS Displays/adjusts an Alternate Overload limit for this AWP*
ACC’Y XXXX LBS (OR KGS) 0 LBS Displays/adjusts a de-rating for Accessories*
OVR DBNCE X S 3 Sec Displays/adjusts the de-bounce delay before an overload.
OVR HOLD X S 5 Sec Displays/adjusts the minimum delay before an overload can be
CAP SEL DLY X S 1 Sec Displays/adjusts the delay before a Capacity Select Digital Input is
FACTORY:
#1 GAIN X.XXXX Displays/calibrates the LSS Module analog channel gain.
#1 ZERO +X.XXXX mV Displa ys/calibrates the LSS Module analog channel offset.
#2 GAIN X.XXXX
#2 ZERO +X.XXXX mV
#3 GAIN X.XXXX Displays/calibrates the LSS Module analog channel gain.
#3 ZERO +X.XXXX mV
#4 GAIN X.XXXX
#4 ZERO +X.XXXX mV
EXC GAIN X.XXXX
TEMP OFFS +XXX.X Displays/calibrates the LSS Module’s internal temp sensor.
* Refer to JLG Workstation in the Sky Accessories™ in Section 2.
Parameter
(Displayed on Analyzer 2
Line)
nd
Default
Values
Note that the Personalities Menu changes based on
MODEL Parameter in the Machine Setup Menu (some displays are suppressed). The information presented below
will be proper when MODEL=BOOM LIFT (refer to
Machine Setup Menu).
To access the Personalities Menu, use the LEFT and
RIGHT Arrow keys to select PERSONALITIES 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 Personalities Menu, and describes the meaning of each parameter.
Description
released.
regarded.
Displays/calibrates the LSS Module analog channel gain.
Displays/calibrates the LSS Module analog channel offset.
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 measu rement gain.
3124287 – JLG Lift – 1-7
SECTION 1 - OPERATION
1.9 MACHINE SETUP MENU
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 BOOM LIFT.
Note that Diagnostics and Personalities Menus change
based on MODEL Parameter (some displays are suppressed).
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 1-4. Machine Setup Menu
Parameter
(Displayed on
Analyzer 2
Line)
MODEL: = BOOM LIFT
UNITS: =LBS
nd
Analyzer 2
=4069LE
=3369LE
=500RTS
=260MRT
=Kg
Parameter Value
(Displayed on
nd
Line)
Description
Displays/adjusts Model Selection. Must be set to BOOM LIFT
for this application.
Displays/adjusts global force
units
1.10 CALIBRATION MENU
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:
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.
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
1-8 – JLG Lift – 3124287
SECTION 1 - OPERATION
90 lbs. (41 kg), but less than 550 lbs.(250 kg). If successful, the Analyzer will show the following:
CALIBRATE:
COMPLETE
If the empty platform weight is greater than 550 lbs.(250
kg), the calibration attempt will be unsuccessful and the
Analyzer will show the following:
CALIBRATE:
> MAX CAL
If the empty platform weight is less than 90 lbs. (41 kg),
the calibration attempt will be unsuccessful and the Analyzer will show the following:
CALIBRATE:
< MIN CAL
3124287 – JLG Lift – 1-9
SECTION 1 - OPERATION
Figure 1-1. LSS Module Analyzer Flow Chart
1-10 – JLG Lift – 3124287
SECTION 1 - OPERATION
1.11 JLG ACCESSORIES, INCLUDING
WORKSTATION IN THE SKY
The Load Sensing System must be configured for proper
operation with JLG approved Accessories. Calibration of
the Load Sensing System can be performed with the
Accessory mounted in the platform.
TM
JLG Approved Accessories (Except SkyGlazier)
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 Sky
ual. 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).
Example: Consider the case of the JLG SkyWelder (SkyCutter) with a De-Rating of 70LBS (32KG). Without De-Rating, the Load Sensing System will declare Overload at
550LBS (250KG) in the 500LBS Capacity Zone (110% of
500LBS) and at 1100LBS (499KG) in the 1000LBS Capacity Zone (110% of 1000LBS). When the De-Rating for SkyWelder (SkyCutter) is entered into the ACC’Y Personality,
the LSS will declare Overload 70LBS (32KG) earlier
(480LBS or 218KG in the 500LBS Capacity Zone;
1030LBS or 467KG in the 1000LBS Capacity Zone).
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).
TM
Accessory Man-
SkyGlazier Accessory
This Accessory does not have a simple De-Rating since it
has different impact on the 500LBS and 1000LBS Capacity Zones (Moment limits in 1000# Zone).
SKYGLAZIER (BASE ONLY)
When not using the SkyGlazier, recommended JLG vehicles can safely carry the SkyGlazier’s Base without impact
on normal capacity ratings.
Procedurally, mount the SkyGlazier’s Base but not the
Tray. Set the LSS Module’s Personalities according to the
table below and perform a Calibration.
Personality Setting
OVERLD 550LBS (249KG)
OVERLD3 1100LBS (499KG)
ACC’Y 0LBS (0KG)
SKYGLAZIER (BASE & TRAY)
When using the SkyGlazier, recommended JLG vehicles
can carry 400LBS (181KG) in the 500LBS Capacity Zone
(Total Platform Weight with Tray Installed), and 750LBS
(340KG) in the 1000LBS Capacity Zone (Total Platform
Weight with Tray Installed).
Procedurally, mount the SkyGlazier’s Base but not the
Tray. Set the LSS Module’s Personalities according to the
table below and perform a Calibration.
Personality Setting
OVERLD 450LBS (204KG)
OVERLD3 800LBS (363KG)
ACC’Y 0LBS ( 0KG)
3124287 – JLG Lift – 1-11
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