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

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.

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

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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 gain.

Displays/calibrates the LSS Module analog channel offset.

Displays/calibrates the LSS Module excitation measu rement gain.

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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

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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

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Figure 1-1. LSS Module Analyzer Flow Chart

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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)

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NOTES:

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SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

SECTION 2. SERVICE - ENGINE POWERED BOOM LIFTS

This section is for servicing 400 Series, 450/510 Series, 600A Series, 600S Series, 800A Series, 800S Series, 1250AJP, & 1200/1350 Series Boom Lifts

2.1 DESCRIPTION

The system consists of the LSS Module, four Shear Beam Load Cells (sensors), Wire Harness, and various brackets and fasteners. The LSS Module is mounted in the platform on a bracket beneath the console box (above the rotator). The Shear Beam Load Cells mount between the platform and the support structure in such a way that all support force for the platform is applied through them (for measurement). The four Shear Beam Load Cells plug directly into the LSS Module. The Wire Harness connects the LSS Module to the Host Control System.

2.2 INSTALLATION

1. Loosen the Fasteners that secure the Platform to the Support Structure. Maneuver the platform above a pair of saw-horses or other adequate supporting device capable of supporting up to 350lbs.(160 kg). Position the platform to a comfortable height. Loosen but do not remove the four 1/2 inch Shank (3/4 inch Head) Hex Bolts that secure the platform to the support.

2. Separate the Platform and Support Structure. tly lower the platform onto the saw-horses or supporting device (using the Auxiliary Power Unit from Ground Control). Remove the fasteners that secure the platform to the support structure and discard the fasteners (new fasteners must be used for installation since all are torqued to specification).

3. Mount the Shear Beam Load Cells to the Support Structure. Carefully examine the detail on Figure 2-

2., Load Sensing System Installation (Sheet 2 of 2) that shows how the components are placed onto the platform support structure. Place one of the Shear Beam Load Cells on top of the support structure with the Orientation Arrow pointing downward (groove near the single mounting hole upward).

Gen-

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Figure 2-1. Load Sensing System Installation (Sheet 1 of 2)

1. Guard

2. Load Cell Assembly

3. Mounting Bracket

4. LSS Module 5 . S hi e ld

2-2 – JLG Lift – 3124287

Figure 2-2. Load Sensing System Installation (Sheet 2 of 2)

1 . C ap s cr e w 2 . N ut

3. Spacer Bushing

4. Load Cell 5 . W as he r

6. Load Cell Guard

DE TA IL A

1. Cable Clamp

2. Button Head Screw

3. Nut 4 . W as he r

5. Load Cell Wire Channel

6. Load Cell Shield

7. Button Head Screw 8 . W as he r

DE TA IL B

1. Load Cell

2. Front Mounting Plate on P la t fo rm S up p or t

3. Load Cell Guard Bracket 4 . W as he r 5 . N ut

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

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Insert the two 1/2 inch Shank (3/4 inch Head) Hex Bolts from above.

4. Install the Wire Channels to the Support Structure.

Install the Load Cell Guard Bracket (2 Left and 2 Right) and Washers below the support structure and secure the Hex Lock Nuts but do not completely tighten (all fasteners will be fully tightened in a subsequent step after alignment to minimize off-axis stress on the sensors).

The channels mount to the Load Cell Guard Brackets and provide protection for the wiring beneath the platform. Mount the channels as shown on Figure 2-

1., Load Sensing System Installation (Sheet 1 of 2) and Figure 2-2., Load Sensing System Installation (Sheet 2 of 2). The large opening is positioned toward the rear of the platform and provides clearance for the sensor’s cable exit. The open part of the channel faces inward (away from the sensor).

Install the remaining three Shear Beam Load Cells in the same fashion. Label each sensor’s connector to avoid confusion in a subsequent step (Front-Left, Front-Right, Rear-Left, Rear-Right).

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Route the rear sensor wiring through the large opening in the channel. An additional shield is supplied for the two Rear Shear Beam Load Cells (to cover the sensor’s cable exit). Mount the cable clamps inside the channel (3 small clamps per side) to properly retain the wiring within the channel. During this step, pull all four Shear Beam Load Cell wires through the channels toward the LSS Module mounting location. Excess wire length should not be allowed to hang below the platform (it will be bundled near the LSS Module).

5. Mount the Platform to the Shear Beam Load Cells. Carefully maneuver the platform support structure toward the platform (using the Auxiliary Power Unit from Ground Control). Make final adjustments by sliding the platform on the saw-horses or barrels. Ensure that sensor wiring is not damaged during this step. Study the Installation Drawing’s detail regarding how components are placed. From below, insert the 5/8 inch Shank bolts (15/16” Head) with washers that mount the Platform to the Shear Beam Load Cells. Place the spacer bushing on top of the Shear Beam Load Cells (between the platform and sensor), with the beveled feature toward the sensor.

Secure the Hex Lock Nut on top of the platform but do not completely tighten.

6. Torque all Fasteners to Specification. that the platform is resting completely on the platform support structure (adjust using the Auxiliary Power Unit from Ground Control). Torque the two 1/2 inch Shank (3/4 inch Head) bolts between the platform support structure and the Shear Beam Load Cell to 75ft-lbs (105 Nm) (do all four sensors), ensuring that the access holes in the Load Cell Guard Brackets for the 5/8 inch Shank bolts remain aligned. Next, torque the 5/8 inch Shank (15/16 inch Head) between the platform and Shear Beam Load Cell to 50 ft-lbs (68 Nm) (do all four sensors).

7. Mount the LSS Module to the Platform. LSS Module to the bracket with the hardware described in the Installation Drawing. Next, mount the assembly to the platform mid-rail (drill mid-rail if necessary).

First, ensure

Secure the

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8. Install the Shear Beam Load Cell Connections. Locate the connector from the Rear-Right Shear Beam Load Cell (orientation from the normal operator’s position while using platform control console). Install the Rear-Right connector into the LSS Module’s J8 by carefully rotating the molded portion of the connector until the keys align, and then tightening the knurled barrel. Tighten it first by hand (avoid cross-threading), and then carefully secure it with a small pair of locking pliers. The connector must be secured in this fashion to compress its O-ring seal and assure moisture resistance, but must not be over-tightened such that it damages the LSS Module. Install the Rear-Left into J7, the Front-Right into J6, and the Front-Left into J5. Neatly bundle the excess wire using wire ties so it can be stowed in the region below the LSS Module mounting location. Ensure that the excess wire length stays within the platform envelope and does not interfere with hydraulic hose movement at the rotator.

position Deutsch connector into J1 on the LSS Module (System Interface – Power & Digital).

Route the harness from the Grey 12-position Deutsch connector into the Platform Console Box via a strain relief connector.

9. Wire the Load Sensing System to the Host Control System. Ensure that the Host Control System is powered-down by depressing the EMS at the Ground Control station. From the wire harness provided, insert the Black 12-position Deutsch connector into J2 on the LSS Module (System Interface – Communication) to install the JLG Analyzer connection. For single capacity vehicles, do not connect the Red/Yellow wire. For dual capacity vehicles, remove the orange contact wedge from the Grey 12-position Deutsch connector and insert the Red/Yellow wire into Socket 9 for vehicles with 500LB / 750LB (230kg / 340kg) Rated Loads or Socket 8 for vehicles with 500LB / 1000LB (230kg / 450kg) Rated Loads. Replace the orange contact wedge, install sealing plugs in the unused sockets, and insert the Grey 12-

Terminate the four harness wires inside the Platform Console Box according to the Wiring Diagram for the Load Sensing System. Match the wire colors and

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numbers from the LSS harness to those of the Host Control System.

10. Install the Overload Lamp at Ground Control if necessary. Open the Main Terminal Box and ensure that the Overload Lamp is installed in the Indicator Panel.

Alternately, observe the Ground Control's Indicator Panel for the Overload Symbol during Power-Up with the Keyswitch in the Ground position. If it is present, skip this step in the procedure. To install the Overload Lamp, first review the AMP Connector section of the vehicle's Service Manual for detailed instructions regarding the connector system.

Next, mount the lamp by inserting it into the opening behind the Overload Symbol and rotating it until it locks. Route the lamp's Brown/White and Black wires from the door toward the Ground Module's J4 connector and secure with wire ties. Remove the J4 Connector (Blue) from the Ground Module by releasing the locking tab with a 3/16 inch (4.8mm) wide screw-

driver blade. Pry the red wedge lock to the open position for contact loading, but do not remove it.

Remove the sealing plugs with a small pair of pliers by rotating them back and forth during removal. Insert the Brown/White wire into J4-14 (lamp output), and the Black into J4-32 (ground). (If J4-32 is already used, connect the Black wire to the ground on the last indicator lamp in the chain.) Close the red wedge lock by squeezing it uniformly inward. Install the J4 connector back into the Ground Module and ensure that the locking tab clicks into position.

11. Setup the Host Control System to enable the Load Sensing System. Power-up the Host Control System by resetting the EMS at the Ground Control station. Plug the JLG Analyzer into the Host Control System’s Analyzer Connection at the Ground or Platform (do not confuse the Host Control System and LSS Module’s Analyzer Connections).

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Enter the Access Level 1 Password (33271). Next, proceed to the MACHINE SETUP, LOAD sub-menu and select “2=CUTOUT PLT”. Press the RIGHT ARROW to view the MACHINE SETUP, LOAD TYPE sub-menu. Set it to “1=4 UNDER BASKET” to select the Load Sensing System with four Shear Beam Load Cells beneath the platform. At this point, it is likely that the Host Control System’s Visual and Audible Warnings for the Load Sensing System will be active (since the LSS Module is un-calibrated).

12. Perform a Calibration of the Load Sensing System. Refer to the Calibration procedure in this manual to prepare the Load Sensing System for use.

2.3 CALIBRATION

Procedure

1. Plug the JLG Analyzer into the LSS Module and enter the Access Level 1 Password. Do not confuse the Host Control System and LSS Module’s Analyzer Connections. The Host Control System’s connection is mounted beneath the Platform Console Box, and the LSS Module’s connection hangs from a short harness near the module. Proceed to the ACCESS LEVEL menu and enter the Access Level 1 Password (33271).

2. Level the Platform. mately level for calibration. Level the platform from Ground Control (if necessary) to within +

3. Configure the LSS Module for Boom Lift mode and Desired Units. Proceed to the LSS Module’s MACHINE SETUP, MODEL sub-menu and select “MODEL=BOOM LIFT”. 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.

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.

The platform should be approxi-

5 degrees.

5. Configure the LSS Module for JLG Accessories. 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 or consult the table within this manual. 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).

6. Execute a Calibration via the JLG Analyzer. 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.

The

Proceed

Te s t i n g & E v al u at i o n

Refer to the Troubleshooting section of this manual if the Load Sensing System fails to meet these guidelines.

1. Plug the JLG Analyzer into the LSS Module. confuse the Host Control System and LSS Module’s Analyzer Connections. The Host Control System’s connection is mounted beneath the Platform Console Box, and the LSS Module’s connection hangs from a short harness near the module.

2. Level the Platform. mately level for analysis, or the guidelines below will not be applicable. Level the platform from Ground Control (if necessary) to within +

3. Observe the Empty Platform Weight. 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 + should be stable and should not vary by more than

2lbs (±1kg) (unless there is heavy influence from

+ wind or vibration).

The platform should be approxi-

5 degrees.

Proceed to the

15lbs (± 7kg). Further, the reading

Do not

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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 20lbs (9kg) (max PLTLOAD reading – min PLTLOAD reading).

5. Confirm Host Control System Warnings and Interlocks. Using the vehicle’s keyswitch, select Platform Mode and power-up. Start the vehicle’s engine 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 Beam Load Cell connected to J5 on the LSS Module (the most easily accessed). 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, all 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. Confirm that controls are responsive when using the Auxiliary Power Unit for emergency movement. Install the disconnected Shear Beam 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 and the Auxiliary Power Unit (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 engine as in the platform). Re-fit the Shear Beam Load Cell 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.

6. Confirm Host Control System Capacity Indication (optional for vehicles with Dual Capacity Ratings). For vehicles equipped with a Capacity Select switch on the Platform Console Box, it is necessary to examine an additional interface between the Load Sensing System and the Host Control System. Using the vehicle keyswitch, select Platform Mode and power-up. If necessary, put the boom in the transport position (completely stowed) and center the Jib Plus (if equipped). Place the Capacity Select switch in the 500lbs (230kg)position and ensure that the proper indicator illuminates on the Platform Console Box. Plug the JLG Analyzer into the LSS Module’s Analyzer connection and proceed to the DIAGNOSTICS, SYSTEM submenu. Ensure that the 750# (340kg) CAPACITY and 1000# (450kg) CAPACITY displays indicate OFF. Place the Capacity Select switch in the 750lbs/1000lbs (340kg/450kg) position (if so equipped) and ensure that the proper indicator illuminates on the Platform Console Box (but does not flash). For vehicles with 750lbs (340kg) capacity, ensure that the 750# (340kg) CAPACITY display indicates ON but the 1000# (450kg) CAPACITY indicates OFF. For vehicles with 1000lbs capacity, ensure that the 750# (340kg) CAPACITY display indicates OFF but the 1000# CAPACITY indicates ON.

7. Confirm Load Sensing System Performance with Calibrated Weights. Operate the vehicle from Ground Control and place the boom in the transport position (fully stowed) for safety. Plug the JLG Analyzer into the LSS Module’s connection and proceed to the DIAGNOSTICS, PLTLOAD display. Place 500lbs (230kg) in the platform and ensure that PLTLOAD is with + Capacity vehicles, do the same for the alternate capacity (750LBS or 1000LBS [340kg or 450kg]).

5% of the actual weight. For Dual

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2.4 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 2-1. LSS Troubleshooting Chart - General

Difficulty Possible Resolution

JLG Analyzer does not display “HELP: PRESS ENTER” when connected to LSS Module’s connection, but the module’s LED is lit or flashing.

LED on LSS Module does not light.

The JLG Analyzer is failing to communicate with the LSS Module, but the LSS Module is powered (indicated by module’s LED). Investigate JLG Analyzer serial communication and power supply connections.

1. If the Analyzer displays “CONNECTING…” or “CONNECTION ERROR” after a short 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.

The LSS Module is un-powered, a short exists, or the device is damaged.

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.

2-10 – JLG Lift – 3124287

Difficulty Possible Resolution

JLG Analyzer displays “<MIN CAL” after attempt is made to Calibrate.

JLG Analyzer displays “>MAX CAL” after attempt is made to Calibrate.

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

Table 2-2. LSS Troubleshooting Chart - Calibration

The LSS Module expected the empty platform to weight more for calibration.

1. The platform is resting on the ground or another obstruction during calibration. The platform’s weight must be transferred through the Shear Beam Load Cells and into the 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 “MODEL=BOOM LIFT”. Improper selection may lead the LSS Module to expect different empty platform weights.

3. One or more shear beams are improperly mounted (there is interference between the platform and support structure) or upside down. Refer to the Installation portion of this manual to resolve the issue.

4. The calibration difficulty may be a result of a Measurement Performance issue. Review the Possible Resolutions under that category.

The LSS Module expects the empty platform to weigh less for calibration.

1. Tools, debris, or customer-installed accessories have not been removed before calibration. 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=BOOM LIFT”. Improper selection may lead the LSS Module to expect different empty platform weights.

3. One or more shear beams are improperly mounted (there is interference between the platform and support structure) or upside down. Refer to the Installation portion of this manual to resolve the issue.

4. The calibration difficulty may be a result of a Measurement Performance issue. Review the Possible Resolutions under that category.

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Table 2-3. LSS Troubleshooting Chart - Measurement Performance

Difficulty Possible Resolution

Empty Platform Weight (DIAGNOSTICS, PLTLOAD) is not within +

Platform Load readings (DIAGNOTICS, PLTLOAD) are unstable by more than +2lbs (±1kg) (without the influence of vibration or wind).

There are large variations in Platform Load (DIAGNOSTICS, PLTLOAD) based on the location of the load. Tolerance to variations is 20lbs for an evaluation using the technician’s weight, and + Rated Load when using calibrated weights.

(continued)

15lbs (±7kg) of zero.

or

5% of

The LSS Module is unable to properly measure the platform weight.

1. One of the Shear Beam Load Cells is not properly plugged into the LSS Module. Since 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. Attempt to wiggle the molded portion of each connector on J5-J8. If properly tightened, the molded portion should not move. Also, examined each Shear Beam Load Cell’s readings via the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and determine if the readings are reasonable. Note that it is possible to have only two sensors carrying all of the platform load due to fit between the platform and support structure (this is normal).

2. Wiring leading to one of the Shear Beam Load Cells is damaged. 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 responsive to slight downward pressure above the sensor being viewed. Carefully inspect sensor wiring where it passes through cable clamps for signs of damage. Inspect wiring where damage to the channel is apparent. If damage to the sensor’s cordset is found, replace the appropriate Shear Beam Load Cell since the cordset is not serviceable (connector is molded for moisture resistance; cordset is soldered into sensor beneath welded stainless steel cover).

3. One of the Shear Beam 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)

2-12 – JLG Lift – 3124287

Table 2-3. LSS Troubleshooting Chart - Measurement Performance

Difficulty Possible Resolution

Empty Platform Weight (DIAGNOSTICS, PLTLOAD) is not within +

Platform Load readings (DIAGNOTICS, PLTLOAD) are unstable by more than +2lbs (±1kg) (without the influence of vibration or wind).

There are large variations in Platform Load (DIAGNOSTICS, PLTLOAD) based on the location of the load. Tolerance to variations is 20lbs for an evaluation using the technician’s weight, and + Rated Load when using calibrated weights.

15lbs (±7kg) of zero.

or

5% of

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

4. Improper procedure was used when tightening the fasteners for the Shear Beam Load Cells. Failure to regard the notes in the Installation guide can result in large offaxis forces on the sensors (which disturb the primary measurement axis readings). Loosen all fasteners and sequentially torque them as recommended in the Installation guide (new fasteners are recommended to achieve proper torque).

5. Damage to the platform or support structure has occurred or one of the components is out-of-tolerance (not planar). When the fasteners are torqued to specification, the sensors are disturbed by large off-axis forces (which disturb the primary measurement axis readings). Loosen all fasteners and observe whether the platform or support were drawn-up by the fasteners (they should both be planar and match up accurately). Resolution is to replace the damaged or faulty component. Watch for Shear Beam Load Cell damage (yield) as a result of this difficulty.

6. One of the Shear Beam 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 + 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 Beam Load Cell itself will require replacement of the sensor.

7. One of the Shear Beam Load Cells has been mechanically damaged (yielded). Any Shear Beam 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 (>6000lbs [>2722kg]). This can be detected by removing all fasteners that mount the platform and supporting the platform on two saw-horses or barrels (no weight resting on the Shear Beam Load Cells). Examine each sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and observe whether the unloaded sensors read with + sive force when physically unloaded.

8. The LSS Module is suspect. Interchange the Shear Beam 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.

15lbs (±7kg) of zero (individually). Replace sensors that read exces-

2lbs (±1kg) (without the influence of vibration or wind).

3124287 – JLG Lift – 2-13

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

Table 2-4. 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 Beam Load Cell from the LSS Module. Controls remain functional at Platform and Ground Control positions.

The Visual and Audible Overload Warnings sound even when the platform is empty. Controls are prevented in the same manner as when overloaded.

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 “2=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. 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 J1-5 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. 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.

The LSS Module is un-powered, un-calibrated, or is experiencing a Measurement Performance difficulty. Alternately, the Host Control System is not receiving the proper signal from the LSS Module.

1. Ensure that the LSS Module is powered. The LSS Module’s LED will be lit or flash if the module is powered. If not, ensure that approximately 12V is present between J11 and J1-2 on the LSS Module (J1-1 is positive). Trace the Ignition and Ground supply wires into the Platform Console Box’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 Platform Module’s J1-20. Refer to the Wiring Diagram for wire color, number, and terminal information.

3. 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.

2-14 – JLG Lift – 3124287

Table 2-4. LSS Troubleshooting Chart - Host System Functionality

Difficulty Possible Resolution

The Ground Audible Warning fails to sound, but the Platform Audible Warning sounds properly.

Controls remain functional at the Ground Control position during an overload, or when simulated by unplugging a Shear Beam from the LSS Module. The Control at the Platform Control position are prevented when using the engine, but not when using the Auxiliary Power Unit.

When the Capacity Select switch is set for 750lbs/1000lbs (340kg/450kg), Visual and Audible Overload Warnings sound and controls are prevented when the platform is loaded beyond 500lbs (230kg). Alternately, the Visual and Audible Overload Warnings do not sound and controls are not prevented when the platform is loaded beyond 500lbs (230kg) but the Capacity Select switch is set for 500lbs (230kg). (Dual Capacity vehicles only).

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

The Host Control System’s Ground Alarm is missing or improperly installed. Verify that the device is mounted. Verify wiring from the Main Terminal Box and Ground Module according to the proper Host Control System documentation. The Ground Alarm is energized from J227 on the Ground Module (approximately 12V). Ensure that the ground termination is proper (0V).

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 “2=CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter to “3=CUTOUT ALL” to prevent platform and ground controls in the event of overload.

There is a malfunction associated with the Capacity Select signal between the Host Control System and LSS Module. This signal is controlled by the Host Control System and is an input to the LSS Module. When the Capacity Select switch is set to 500lbs (230kg), this signal is de-energized (0V). The signal is energized (12V) when the Capacity Select switch is set to 750lbs/1000lbs (340kg/450kg). This signal will be connected to J1-8 on the LSS Module for vehicles that carry up to 750lbs (340kg), and J1-9 for vehicles that carry up to 1000lbs (450kg).

1. Observe operation of the Platform Console Box’s Capacity Indicator Lamps. Place the boom in the transport position (fully stowed) and center the Jib Plus (if equipped) to enable selection of both capacities. Set the keyswitch to the Platform position and power-up. When the Capacity Select switch on the Platform Console Box is in the 500lbs (230kg) position, ensure that the 500lbs (230kg) Indicator Lamp is lit. When the Capacity Select switch is in the 750lbs/1000lbs (340kg/450kg) position, ensure that the 750lbs/1000lbs (340kg/450kg) Indicator Lamp is lit. If either does not occur, ensure that J1-21 on the Platform Module is de-energized (0V) when the Capacity Select switch is in the 500lbs (230kg) position, and energized (12V) when the switch is in the 750lbs/1000lbs (340kg/450kg) position. Ensure that J2-12 on the Platform Module is energized (12V) when the Capacity Select switch is in the 500LBS position. Ensure that J2-13 on the Platform Module is energized (12V) when the Capacity Select switch is in the 750lbs/1000lbs (340kg/450kg) position. Finally, is may be necessary to consult documentation for the Host Control System to determine if another safety interlock is preventing the vehicle from entering the 750lbs/1000lbs (340kg/450kg) mode.

2. Remove the J1 (Grey) connector from the LSS Module and measure voltage on this signal (J1-8 for 750lbs [340kg] or J1-9 for 1000lbs [450kg]). Plug the JLG Analyzer into the LSS Module’s connection and proceed to DIAGNOSTICS, SYSTEM. The 750# CAPACITY display will indicate “ON” when J1-8 is energized (12V) and “OFF” when J1-8 is de-energized (0V). The 1000# (450kg) CAPACITY display will indicate “ON” when J1-9 is energized (12V) and “OFF” when J1-9 is de-energized (0V). If the LSS Module fails to respond properly to signals on J1-8 or J1-9, then the LSS Module is suspect (substitute to determine cause of failure).

3124287 – JLG Lift – 2-15

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

Figure 2-3. LSS Module Load Cell Connector

Pinout (J5, J6, J7, J8)

NOTE: Physical connector as viewed looking into the

cable end

Table 2-7. LSS Module Load Cell Connector Pinout (J5,

Table 2-5. LSS Module System Interface Connector -

Power & Digital (J1 - Grey)

Pin Signal Description

1 VBAT Po sitive Power Supply from Host Control System

(12-24V)

2 GND Negative Power Supply from Host Control Sy stem

(0V)

3 GND-2 Connects to GND

4N/CUnused

5 DO1 Overload Indicator Ou tput (Normal=VBAT / Over-

load=0V)

6 DO2 Warning Indicator Output (Normal=0V / Over-

loaded=VBAT for 5 Sec, 0V for 2 Sec)

7DI3Unused

8 DI 2 Select OV ERLD3 Personality Rating (No=0V /

Yes =V BA T)

9 DI 1 Select OV ERLD2 Personality Rating (No=0V /

Yes =V BA T)

10 GND-2 Connects to GND

11 VBAT-2 Connects to VBAT

12 VBAT-2 Connects to VBAT

Pin Signal Description

1 + Signal Positive Sensor Output (approx. 2.5V)

2 Cal Clock Serial Clock to Sensor’s Integrated Memory

3 - Excitation Negative Sensor Supply Voltage (approx. 0V)

4 +Excitation Positive Sensor Supply Voltage (approx. 5V)

5 - Signal Negative Sensor Output (approx. 2.5V)

6 Cal Data Serial Data from Sensor’s Integral Memory

J6, J7, J8)

Table 2-6. 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 RS-232 for JLG Analyzer (Analyzer Pin 3)

3 TRP1 120 Ohm CANbus Terminator

4 CANH-1 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 (Anal yzer Pin 4)

2-16 – JLG Lift – 3124287

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

4933278 F 4933289 A

(

ANA

LYZ

E

R

C

ONNECTOR)

SOCKE

T

10S

OCK

E

T

1

1 GREENSO

CKE

T 1

2 B

LACK/SHIE

L

D

S

OCKET 1 R

EDSOC

K

E

T

3

W

H

ITE

S

O

C

KET 2 GREEN

S

OCKET 4 BLA

CK/SHIELD

P

I

N

1

+

SIGNALP

I

N

2

CAL CLOCKPI

N

3

-

EX

CIT

ATIONPI

N

4 + EX

CITATIO

NPI

N 5 - SIGNA

LPI

N

7

CAL DAT

A

BLACK

ORN/RED 49-100 J4-14

PLATFORM

OVERLOAD

LAMP

LOCATED IN GROUND CONTROL BOX

J8

REAR RIGHT

LOAD C ELL

J7

REAR LEFT

LOAD CE LL

J6

FRONT RIGHT

LOAD C ELL

J5

FRONT LEFT

LOAD C ELL

V+ BATT

PLATFORM CONSOLE BOX

(EIM OUTPUT)

J1 GRAY

E300A/AJ/AJP - E/M400AJ/AJP

E/M450A/AJ - E/M600/J/JP

150HAX - 400S - 450A/AJ

450A/AJ Series II

510AJ - 600S/SC/SJ/SJC

660SJ/SJC - 800A/AJ

800S/SJ - 1200SJP

1250AJP - 1350SJP

1500SJ

OR

J2 BLACK

J3-4

INSTALL INTO

(PIN 14) OF 15

POSITION

MATE-N-LOCK

1000#/750KG

1000# CAPACITY LIGHT

750# CAPACITY LIGHT

RED/YEL 54-3-1

YEL/RED 2-37 TO (PIN 15)

15 POSITION MATE-N-LOCK

BLACK J1-4

LED BOARD

TERMINAL STRIP IS LOCATED ON THE

LEFT SIDE OF THE CONSOLE BOX BOTTOM.

TERMINAL STRIP IS LOCATED ON T HE

LEFT SIDE OF THE CONSOLE BOX BOTTOM.

(CAPACITIY INPUT)

(GROUND)

1

2

3

4

5

6

J2-25 BLACK

J2-13 RED/YEL 54-3

SOCKET 2 WHT/BLK 58-8

SOCKET 5 BRN/WHT 47-9

SOCKET 8

SOCKET 9

SOCKET 3

SOCKET 6

SOCKET 10

SOCKET 11

SOCKET 12

SOCKET 4

SOCKET 1 WHT/RED 57-5

WHT/BLK 58-8

BRN/WHT 47-9

12345

6

WHT/RED 57-5

PLATFORM POWER MODULE

J2

1

2

53364

J7

J8

WHT/RED 57-5

WHT/BLK 58-8

BRN/WHT 47-9

SOCKET 1 RED

SOCKET 2 WHITE

SOCKET 3

SOCKET 4

SOCKET 5

SOCKET 6

SOCKET 4

SOCKET 1 YEL/RED 2-36

SOCKET 2 BLACK

SOCKET 5 YEL/RED 2-37

SOCKET 8 RED/YEL 54-2-1

SOCKET 9 RED/YEL 54-2-1

SOCKET 3

SOCKET 6

SOCKET 10

SOCKET 11

SOCKET 12

SOCKET 4

J1 GREY

J2 BLACK

REAR LEFT

LOAD P IN (RL)

FRONT LEFT

LOAD PIN (FL)

FRONT RIGHT

LOAD PIN (FR)

REAR RIGHT

LOAD PIN (RR)

J1 NOTE

INSTALL RED/YEL 54-2-1 INTO SOCKET 8 FOR 1000LB CA PACITY.

INSTALL RED/YEL 54-2-1 INTO SOCKET 9 FOR 750LB CA PACITY.

NOTE: RED/YEL 54-2-1 NOT REQUIRED ON 500LB C APACITY

MACHINES. PLEASE INSTALL ONE WIRE CAP (4460121)

ON THE RED/YEL 54-2-1 WIRE AT THE J1 CONNECTOR.

ALWAYS INSTALL THE OTHER END OF THIS WIRE TO

TERMINAL STRIP IN #1 POSITION .

INSTALL RED/YEL 54-2-1 FROM SOCKET 9 TO TO S OCKET 12 FOR

400S WITH 750 LB CAPACITY

Figure 2-4. Wiring Diagram

3124287 – JLG Lift – 2-17

SECTION 2 - SERVICE - ENGINE POWERED BOOM LIFTS

NOTES:

2-18 – JLG Lift – 3124287

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

SECTION 3. SERVICE - ELECTRIC POWERED BOOM LIFTS

This section is for servicing E300 Series, E/M400 Series, E/M450 Series, & E/M600 Series Boom Lifts

3.1 DESCRIPTION

The system consists of the LSS Module, four Shear Beam Load Cells (sensors), Wire Harness, and various brackets and fasteners. The LSS Module is mounted in the platform on a bracket beneath the console box (above the rotator). The Shear Beam Load Cells mount between the platform and the support structure in such a way that all support force for the platform is applied through them (for measurement). The four Shear Beam Load Cells plug directly into the LSS Module. The Wire Harness connects the LSS Module to the Host Control System.

3.2 INSTALLATION

1. Loosen the Fasteners that secure the Platform to the Support Structure. Maneuver the platform above a pair of saw-horses or other adequate supporting device capable of supporting up to 350lbs.(160 kg). Position the platform to a comfortable height. Loosen but do not remove the four 1/2 inch Shank (3/4 inch Head) Hex Bolts that secure the platform to the support.

2. Separate the Platform and Support Structure. tly lower the platform onto the saw-horses or supporting device (from Ground Control). Remove the fasteners that secure the platform to the support structure and discard the fasteners (new fasteners must be used for installation since all are torqued to specification).

3. Mount the Shear Beam Load Cells to the Support Structure. Carefully examine the detail on Figure 3-

2., Load Sensing System Installation (Sheet 2 of 2) that shows how the components are placed onto the platform support structure. Place one of the Shear Beam Load Cells on top of the support structure with the Orientation Arrow pointing downward (groove near the single mounting hole upward).

Gen-

3124287 – JLG Lift – 3-1

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

Figure 3-1. Load Sensing System Installation (Sheet 1 of 2)

1. Guard

2. Load Cell Assembly

3. Mounting Bracket

4. LSS Module 5 . S hi e ld

3-2 – JLG Lift – 3124287

Figure 3-2. Load Sensing System Installation (Sheet 2 of 2)

1 . C ap s cr e w 2 . N ut

3. Spacer Bushing

4. Load Cell 5 . W as he r

6. Load Cell Guard

DE TA IL A

1. Cable Clamp

2. Button Head Screw

3. Nut 4 . W as he r

5. Load Cell Wire Channel

6. Load Cell Shield

7. Button Head Screw 8 . W as he r

DE TA IL B

1. Load Cell

2. Front Mounting Plate on P la t fo rm S up p or t

3. Load Cell Guard Bracket 4 . W as he r 5 . N ut

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

3124287 – JLG Lift – 3-3

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

Insert the two 1/2 inch Shank (3/4 inch Head) Hex Bolts from above.

4. Install the Wire Channels to the Support Structure. The channels mount to the Load Cell Guard Brack-

Install the Load Cell Guard Bracket (2 Left and 2 Right) and Washers below the support structure and secure the Hex Lock Nuts but do not completely tighten (all fasteners will be fully tightened in a subsequent step after alignment to minimize off-axis stress on the sensors).

ets and provide protection for the wiring beneath the platform. Mount the channels as shown on Figure 3-

1., Load Sensing System Installation (Sheet 1 of 2) and Figure 3-2., Load Sensing System Installation (Sheet 2 of 2). The large opening is positioned toward the rear of the platform and provides clearance for the sensor’s cable exit. The open part of the channel faces inward (away from the sensor).

Install the remaining three Shear Beam Load Cells in the same fashion. Label each sensor’s connector to avoid confusion in a subsequent step (Front-Left, Front-Right, Rear-Left, Rear-Right).

3-4 – JLG Lift – 3124287

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

Route the rear sensor wiring through the large opening in the channel. An additional shield is supplied for the two Rear Shear Beam Load Cells (to cover the sensor’s cable exit). Mount the cable clamps inside the channel (3 small clamps per side) to properly retain the wiring within the channel.

During this step, pull all four Shear Beam Load Cell wires through the channels toward the LSS Module mounting location. Excess wire length should not be allowed to hang below the platform (it will be bundled near the LSS Module).

feature toward the sensor. Secure the Hex Lock Nut on top of the platform but do not completely tighten.

6. Torque all Fasteners to Specification. that the platform is resting completely on the platform support structure (adjust using the Ground Control). Torque the two 1/2 inch Shank (3/4 inch Head) bolts between the platform support structure and the Shear Beam Load Cell to 75ft-lbs (105 Nm) (do all four sensors), ensuring that the access holes in the Load Cell Guard Brackets for the 5/8 inch Shank bolts remain aligned. Next, torque the 5/8 inch Shank (15/16 inch Head) between the platform and Shear Beam Load Cell to 50 ft-lbs (68 Nm) (do all four sensors).

7. Mount the LSS Module to the Platform. LSS Module to the bracket with the hardware described in the Installation Drawing. Next, mount the assembly to the platform mid-rail (drill mid-rail if necessary).

First, ensure

Secure the

5. Mount the Platform to the Shear Beam Load Cells. Carefully maneuver the platform support structure toward the platform (from Ground Control). Make final adjustments by sliding the platform on the sawhorses or barrels. Ensure that sensor wiring is not damaged during this step. Study the Installation Drawing’s detail regarding how components are placed. From below, insert the 5/8 inch Shank bolts (15/16” Head) with washers that mount the Platform to the Shear Beam Load Cells. Place the spacer bushing on top of the Shear Beam Load Cells (between the platform and sensor), with the beveled

3124287 – JLG Lift – 3-5

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

8. Install the Shear Beam Load Cell Connections. Locate the connector from the Rear-Right Shear Beam Load Cell (orientation from the normal operator’s position while using platform control console). Install the Rear-Right connector into the LSS Module’s J8 by carefully rotating the molded portion of the connector until the keys align, and then tightening the knurled barrel. Tighten it first by hand (avoid cross-threading), and then carefully secure it with a small pair of locking pliers. The connector must be secured in this fashion to compress its O-ring seal and assure moisture resistance, but must not be over-tightened such that it damages the LSS Module. Install the Rear-Left into J7, the Front-Right into J6, and the Front-Left into J5. Neatly bundle the excess wire using wire ties so it can be stowed in the region below the LSS Module mounting location. Ensure that the excess wire length stays within the platform envelope and does not interfere with hydraulic hose movement at the rotator.

Install a strain relief connector into the platform box and route the harness from the Grey 12-position Deutsch connector into the Platform Console Box.

Route the wires under the module. Terminate the three harness wires inside the Platform Console Box according to the Wiring Diagram for the Load Sensing System. Match the wire colors and numbers from the LSS harness to those of the Host Control System.

9. Wire the Load Sensing System to the Host Control System. Ensure that the Host Control System is powered-down by depressing the EMS at the Ground Control station. From the wire harness provided, insert the Black 12-position Deutsch connector into J2 on the LSS Module (System Interface – Communication) to install the JLG Analyzer connection. Plug the Deutsch connector into J1 on the LSS Module (System Interface – Power & Digital).

10. Setup the Host Control System to enable the Load Sensing System. Power-up the Host Control System by resetting the EMS at the Ground Control station. Plug the JLG Analyzer into the Host Control System’s Analyzer Connection at the Ground or Plat-

3-6 – JLG Lift – 3124287

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

form (do not confuse the Host Control System and LSS Module’s Analyzer Connections).

Enter the Access Level 1 Password (33271). Next, proceed to the MACHINE SETUP, LOAD sub-menu and select “2=CUTOUT PLT”. Press the RIGHT ARROW to view the MACHINE SETUP, LOAD TYPE sub-menu. Set it to “1=4 UNDER BASKET” to select the Load Sensing System with four Shear Beam Load Cells beneath the platform. At this point, it is likely that the Host Control System’s Visual and Audible Warnings for the Load Sensing System will be active (since the LSS Module is un-calibrated).

11. Perform a Calibration of the Load Sensing System. Refer to the Calibration procedure in this manual to prepare the Load Sensing System for use.

3.3 CALIBRATION

Procedure

1. Plug the JLG Analyzer into the LSS Module and enter the Access Level 1 Password. Do not confuse the Host Control System and LSS Module’s Analyzer Connections. The Host Control System’s connection is mounted beneath the Platform Console Box, and the LSS Module’s connection hangs from a short harness near the module. Proceed to the ACCESS LEVEL menu and enter the Access Level 1 Password (33271).

2. Level the Platform. mately level for calibration. Level the platform from Ground Control (if necessary) to within +

3. Configure the LSS Module for Boom Lift mode and Desired Units. Proceed to the LSS Module’s MACHINE SETUP, MODEL sub-menu and select “MODEL=BOOM LIFT”. 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.

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.

5. Configure the LSS Module for JLG Accessories. 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 or consult the table within this manual. 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).

6. Execute a Calibration via the JLG Analyzer. 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.

The platform should be approxi-

5 degrees.

The

Proceed

3124287 – JLG Lift – 3-7

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

Te s t i n g & E v al u at i o n

Refer to the Troubleshooting section of this manual if the Load Sensing System fails to meet these guidelines.

1. Plug the JLG Analyzer into the LSS Module. confuse the Host Control System and LSS Module’s Analyzer Connections. The Host Control System’s connection is mounted beneath the Platform Console Box, and the LSS Module’s connection hangs from a short harness near the module.

2. Level the Platform. mately level for analysis, or the guidelines below will not be applicable. Level the platform from Ground Control (if necessary) to within +

3. Observe the Empty Platform Weight. 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 + 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. cian 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 20lbs (9kg) (max PLTLOAD reading – min PLTLOAD reading).

The platform should be approxi-

5 degrees.

Proceed to the

15lbs (± 7kg). Further, the reading

Do not

The techni-

5. Confirm Host Control System Warnings and Interlocks. Using the vehicle’s keyswitch, select Platform Mode and power-up. 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 Beam Load Cell connected to J5 on the LSS Module (the most easily accessed). The Overload Visual Warning in the platform should flash, and the Audible Warning (at Platform and Ground) should sound for 5 seconds On, and 2 seconds Off. All controls should be prevented. Install the disconnected Shear Beam 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 (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 as in the platform). Re-fit the Shear Beam Load Cell 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.

6. Confirm Load Sensing System Performance with Calibrated Weights. Operate the vehicle from Ground Control and place the boom in the transport position (fully stowed) for safety. Plug the JLG Analyzer into the LSS Module’s connection and proceed to the DIAGNOSTICS, PLTLOAD display. Place 500lbs (230kg) in the platform and ensure that PLTLOAD is with +

5% of the actual weight.

3-8 – JLG Lift – 3124287

SECTION 3 - SERVICE - ELECTRIC POWERED BOOM LIFTS

3.4 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 3-1. LSS Troubleshooting Chart - General