JLG LSS Boom User Manual

Download

Operation & Safety,

Service & Maintenance, &

Illustrated Parts Manual Supplement

JLG

LOAD

SENSING

SYSTEM

Scissors Lift Products

P/N

3124288

July 26, 2013

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

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.

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 SERVICEMANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

• NEVER WORK UNDER AN ELEVATED SIZZOR UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

•BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-

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.

MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3124288 – JLG Lift – A-1

INTRODUCTION

REVISION LOG

Original Issue - June 13, 2003 Revised - July 28, 2003 Revised - August 11, 2003 Revised - September 12, 2003 Revised - March 1, 2004 Revised - October 15, 2004 Revised - July 15, 2006 Revised - October 26, 2007 Revised - June 4, 2010 Revised - March 31, 2011 Revised - March 1, 2012 Revised - August 11, 2012 Revised - January 30, 2013 Revised - July 26, 2013

A-2 – JLG Lift – 3124288

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 - ANALYZER OPERATION - ALL

1.1 Introduction & Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Viewing & Adjusting Parameters Using the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . .1-3

SECTION 2 - OPERATION - (LE, MRT, RTS)

2.1 Connecting the JLG Control System Analyzer (LE, MRT & RTS). . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Help Menu & Fault Codes (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Diagnostic Menu (LE, MRT & RTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.4 Personalities (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.5 Machine Setup Menu (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.6 Calibration Menu (LE, MRT & RTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.7 JLG Workstation in the Sky™ Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

SECTION 3 - OPERATION - (ES, RT)

3.1 Connecting the JLG Control System Analyzer (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Help Menu & Fault Codes (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Diagnostic Menu (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.4 Personalities (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.5 Machine Setup Menu (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3.6 Calibration Menu (ES & RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

SECTION 4 - OPERATION - (RS)

4.1 Connecting the JLG Control System Analyzer (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Help Menu & Fault Codes (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 Diagnostic Menu (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.4 Personalities MENU (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.5 Calibration Menu (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Angle Sensor Calibration (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.6 Load Sensing System Calibration (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

SECTION 6 - SERVICE - (RS)

6.1 Description (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 Calibration (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Angle Sensor Calibration Procedure (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Platform Load Sensing System Calibration Procedure (RS) . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 Testing and Evaluation (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.4 LSS Troubleshooting (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6.5 LSS Component Removal/Installation (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Pressure Transducer Removal (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Pressure Transducer Installation (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

3124288 – JLG Lift – i

TABLE OF CONTENTS (Continued)

10RS Angle Sensor Removal (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

10RS Angle Sensor Installation (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6RS Angle Sensor Removal (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6RS Angle Sensor Installation (RS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

LSS Connector Pin Assignments (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

SECTION 7 - PARTS

7-1 Load Sensing System Installation (260MRT, M3369/M4069 & 3369LE/4069LE) . . . . . . . . . . . . .7-2

7-2 Load Sensing System Installation (500RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-3 Load Sensing System Installation (1930ES/2032ES/2630ES/ 2646ES/3246ES) . . . . . . . . . . . . .7-8

7-4 Load Sensing System Installation (6RS/10RS/1932RS/3248RS). . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7-5 Load Sensing System Installation (3394RT/4394RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Module Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

3-1. Module Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

5-1. Load Sense Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-2. LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-3. 260MRT Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-4. M3369/M4069 & 3369LE/4069LE Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-5. 500RTS Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-6. ES Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-7. RT Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

6-1. LSS Pressure Transducers Location - 1932RS/6RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-2. LSS Pressure Transducers Location - 3248RS/10RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-3. LSS - Scissor Arm Angle Sensor - (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-4. LSS - Electrical Component Schematic - (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

2-1 LSS Fault Codes (LE, MRT and RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-2 Diagnostic Menu Descriptions (LE, MRT & RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-3 Personalities Menu Description (LE, MRT, RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-4 Machine Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-5 Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-6 LSS Module Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3-1 LSS Fault Codes (LE, MRT and RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2 Diagnostic Menu Descriptions (ES & RT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3 Personalities (ES & RT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-4 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-5 Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

4-1 LSS Fault Codes (RS ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 Diagnostic Menu Descriptions (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-3 Personalities Menu Description (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-4 Angle Sensor Calibration Failure Troubleshooting (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-5 Load Calibration Failure Troubleshooting (RS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

5-1 LSS Troubleshooting Chart - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-2 LSS Troubleshooting Chart - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

ii – JLG Lift – 3124288

TABLE OF CONTENTS

5-3 LSS Troubleshooting Chart - Measurement Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-4 LSS Troubleshooting Chart - Host System Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-5 LSS Module System Interface Connector - Power & Digital (J1 - Grey) . . . . . . . . . . . . . . . . . . . .5-10

5-6 LSS Module System Interface Connector – Communication (J1 - Black) . . . . . . . . . . . . . . . . . . .5-10

5-7 LSS Module Load Cell Connector Pinout (J5, J6, J7, J8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

6-1 Platform Calibration Weight - RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2 System Activation Height - RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-3 LSS Troubleshooting - RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6-4 Connections to Host Control System (J1-Black) (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-5 Connections to Host Control System (J2-Blue) (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-6 Angle Sensor Connector Pinout (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-7 Pressure Transducer Connector Pinout (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

3124288 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

NOTES:

iv – JLG Lift – 3124288

SECTION 1 - ANALYZER OPERATION - ALL

SECTION 1. ANALYZER OPERATION - ALL

NOTE: This manual is intended as a supplement to the 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. If the actual platform load exceeds the selected Rated Load, the following will occur:

1. The Overload Visual Warning Indicator will flash at the selected control position (platform or ground).

2. The Platform and Ground Alarms will sound 5 seconds On, and 2 seconds Off.

3. All normal movement will be prevented from the platform control position (optional - ground control functions may be prevented).

4. Further movement is permitted by:

a. Removing the excess platform load until actual

platform load is less than Rated Load.

b. By an authorized person at the ground control

position (optional - ground control functions may be prevented).

THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF THE FOLLOWING CONDITIONS OCCUR:

a. LSS System initial installation

b. LSS Module replacement

c. LSS Sensor removal or replacement

d. Addition or removal of certain platform mounted

accessories. (Refer to Calibration in Section 2)

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

Calibration of the Load Sensing System is performed by connecting the JLG Analyzer (Analyzer Kit, JLG part no.

2901443). All calibration procedures are menu driven through the use of the Analyzer.

1.2 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.

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 a Help Message.

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.

Pressing ENTER while viewing any of the above menu entries will display additional sub-menus. Typically, the sub-menu is where parameter information is displayed or changed. You may only view Personality settings while in Access Level 2. Access Level 1 is required to change Personality settings and calibrate.

3124288 – JLG Lift – 1-1

SECTION 1 - ANALYZER OPERATION - ALL

The ESC key may be used to leave a sub-menu at any time.

1.3 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER

When the analyzer is first connected, you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level, the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu. For example:

Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly:

MENU: ACCESS LEVEL 1

Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.

MENU: ACCESS LEVEL 2

Press ENTER to select the ACCESS LEVEL menu.

Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the password.

Use the UP or DOWN arrow key to enter the second digit of the password which is 33271.

Continue using the arrow keys until all the remaining digits of the password is shown.

1-2 – JLG Lift – 3124288

1.4 VIEWING & ADJUSTING PARAMETERS

PERS O NALITIES: DRI V E A CCEL 3 . 0 s

USING THE HAND HELD ANALYZER

Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example:

SECTION 1 - ANALYZER OPERATION - ALL

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.

PERSONALITIES: OVR DEBNCE 3.0s

3124288 – JLG Lift – 1-3

SECTION 1 - ANALYZER OPERATION - ALL

NOTES:

1-4 – JLG Lift – 3124288

SECTION 2 - OPERATION - (LE, MRT, RTS)

SECTION 2. OPERATION - (LE, MRT, RTS)

2.1 CONNECTING THE JLG CONTROL SYSTEM ANALYZER (LE, MRT & RTS)

THE LOAD SENSING SYSTEM MODULE HAS AN INDEPENDENT ANALYZER CONNECTION LOCATED NEAR THE MODULE. DO NOT CONFUSE IT WITH THE ANALYZER CONNECTION FROM THE HOST CONTROL SYSTEM.

1. Connect the cable supplied with the Analyzer to the LSS Module located beneath the platform and connect the remaining end of the cable to the analyzer.

NOTE: The cable has a four-pin connector at each end of

the cable; The cable cannot be connected backwards.

2. Power-up the Control System by turning the key to the Platform or Ground position and pulling both emergency stop buttons.

Table 2-1. LSS Fault Codes (LE, MRT and RTS)

Help/Logged

Message

Everything OK LED ON The "Normal" Help Message

<MIN CAL Calibration attempt Unsuccessful, Empty Platform appears to weigh too little. Improper Model Selection (Machine

>MAX CAL Calibration attempt Unsuccessful, Empty Platform appears to weigh too much. This situation has the same root causes

BATT TOO LOW 4/1 Incoming Supply Voltage <9.0 Vdc. The control system’s battery voltage is too low due to excessive electrical load or

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-charg-

C E L L # 1 E R R O R 8 / 1 C e l l # 1 ’ s B r i dg e < 2 V, > 3 V, o r c o u l d n o t r e a d C e l l #1’s Internal Memory. This situation indicates damage to the sensor

C E L L # 2 E R R O R 8 / 2 C e l l # 2 ’ s B r i dg e < 2 V, > 3 V, o r c o u l d n o t r e a d C e l l #2’s Internal Memory. This situation indicates damage to the sensor

C E L L # 3 E R R O R 8 / 3 C e l l # 3 ’ s B r i dg e < 2 V, > 3 V, o r c o u l d n o t r e a d C e l l #3’s Internal Memory. This situation indicates damage to the sensor

C E L L # 4 E R R O R 8 / 4 C e l l # 4 ’ s B r i dg e < 2 V, > 3 V, o r c o u l d n o t r e a d C e l l #4’s Internal Memory. This situation indicates damage to the sensor

WATCHDOG RST 9/1 Microprocessor’s Watchdog Timer Tr iggered. This is an indication that the LSS Module has been exposed to excessive

EEPROM ERROR 9/2 Memor y used to retain Personality/Machine Setup/Calibration has been corrupted and must be reset by verifying all

NO CAL 9/3 Calibration has not been successfully completed. A new LSS Module will display this message until properly cali-

Flash Code

Setup) may cause the LSS Module to expect the wrong Empty Platform Weight. This also may be caused by a damaged sensor or associated wiring. Finally, this condition may occur if mechanical interference between the platform and support structure exists (all weight must transfer through sensors).

as the "<MIN CAL" Fault Message.

discharge.

ing or improper charger operation.

or its wiring.

electrical noise, or has experienced a hardware difficulty.

entries and re-calibrating.

brated.

2.2 HELP MENU & FAULT CODES (LE, MRT & RTS)

The Help Menu is a troubleshooting tool to communicate detected System Faults to the technician. The following table documents the Faults for the Load Sensing System. To access the Help Menu, use the LEFT and RIGHT arrow keys to select HELP: PRESS ENTER from the Top Level Menu. Press the ENTER key to view the menu.

When accessing the Help Menu, the JLG Analyzer will display EVERYTHING OK if the platform is not overloaded and no difficulties are detected. Otherwise, the JLG Analyzer will display OVERLOADED.

In the event of difficulty, the user can press ENTER again to display Logged Help, which is a record of the last 16 Fault Messages. The following table lists each Help/ Logged Message, the Flash Code (for each Fault, the module will flash the two-digit code on its LED) triggered by the Fault, and a Description of the Situation (cause).

Description of Situation

3124288 – JLG Lift – 2-1

SECTION 2 - OPERATION - (LE, MRT, RTS)

Table 2-1. LSS Fault Codes (LE, MRT and RTS)

Help/Logged

Message

INTERNAL ERR 9/9 Pin excitation <4.25 V. The sensors may be excessively loading the excitation supply, or the LSS Module may have

Flash Code

hardware difficulty.

High Side Driver Error. The load attached to OUT1 or OUT2 is shor ted to battery or ground and has been detected by the LSS module.

DRDY Interrupt from A/D missing. This may indicate an LS S Module hardware difficulty.

Description of Situation

2-2 – JLG Lift – 3124288

SECTION 2 - OPERATION - (LE, MRT, RTS)

2.3 DIAGNOSTIC MENU (LE, MRT & RTS)

The Diagnostic Load Menu is another troubleshooting tool for the Load Sensing System. Sensor and status information is presented in real-time for the technician. Several sub-menus exist to organize the data.

Note that the Diagnostic Menu changes based on MODEL Parameter in the Machine Setup Menu (some displays are suppressed). The information presented in the following table will be proper when MODEL=3369LE/4069LE/ 500RTS or 260MRT (refer to Machine Setup Menu).

Table 2-2. Diagnostic Menu Descriptions (LE, MRT & RTS)

Diagnostics Menu

(Displayed on Analyzer 1

CELL 1:

CELL 2:

CELL 3:

CELL 4:

SYSTEM:

Line)

Parameter (Displayed

on Analyzer 2

Line)

PLTLOAD +XXXX LBS or Kg Displays (Total Measured Force – Empty Platform

PLTGROS +XXXX LBS or Kg Displays Total Measured Force (Sum of Pins 1 thru 4

OVERLOADED? Yes / N o Displays Current LSS Module Overload Status

LOAD +

RDG +XX.XXXX mV/V Displays Pin Reading in mV/V

INPUT +

GAIN XXXX.X Displays calibration factor from pin

LOAD +

RDG +

INPUT +

GAIN XXXX.X Displays calibration factor from pin

LOAD +

RDG +

INPUT +

GAIN XXXX.X Displays calibration factor from pin

LOAD +

RDG +

INPUT +

GAIN XXXX.X Displays calibration factor from pin

OVLOAD STAT OFF / ON State of Overload Status Digital Output

WARNING OFF / ON State of Warning Digital Output

MOT INHIBIT NO / YES Status of Internal Motion Inhibit Flag

MOTION #1 OFF / ON Status of Digital Input #1

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 (PIN 1, PIN 2, etc.). To access a sub-menu, press the ENTER key. Once in a sub-menu, press the LEFT and RIGHT Arrow keys to view the various displays (just like a Top Level menu). To exit a sub-menu, press the ESC key.

The table below details the structure of the Diagnostic Menu, and describes the meaning of each piece of information presented.

Parameter Value

(Displayed on Analyzer 2

Description

Line)

Calibration)

LOAD)

XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units

XX.XXXX mV Displays Pin Reading in mV

XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units

XX.XXXX mV/V Displays Pin Reading in mV/V

XX.XXXX mV Displays Pin Reading in mV

XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units

XX.XXXX mV/V Displays Pin Reading in mV/V

XX.XXXX mV Displays Pin Reading in mV

XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units

XX.XXXX mV/V Displays Pin Reading in mV/V

XX.XXXX mV Displays Pin Reading in mV

3124288 – JLG Lift – 2-3

SECTION 2 - OPERATION - (LE, MRT, RTS)

Table 2-2. Diagnostic Menu Descriptions (LE, MRT & RTS)

Diagnostics Menu

(Displayed on Analyzer 1

VERSIONS:

Line)

Parameter (Displayed

on Analyzer 2

Line)

Parameter Value

(Displayed on Analyzer 2

Line)

Description

MOTION #2 OFF / ON Status of Digital Input #2

MOTION #3* OFF / ON Status of Digital Input #3

BATTERY XX.XXV Displays Current Battery Voltage

EXCITE X.XXXXV Displays Load Pin Excitation Voltage

TEMP +/-XXX.X Deg C Display the Temperature Sensed by the LSS Module

for Scissor Pin Compensation

SOFTWARE PX.XX Displays LSS Module Software Version

HARDWARE X Display LSS Module Hardware Revision

ANALYZER VX.XXXX Displays Analyzer Software Version

2-4 – JLG Lift – 3124288

2.4 PERSONALITIES (LE, MRT & RTS)

SECTION 2 - OPERATION - (LE, MRT, RTS)

NOTE: The following parameter adjust performance of the

Load Sensing System. All adjustments must be made at access level 1 (33271).

Table 2-3. Personalities Menu Description (LE, MRT, RTS)

Personalities

(Displayed on

Analyzer 1st line)

FAC TORY #1 G AIN

Parameter (Displayed On Analyzer 2nd line)

OVERLD XXXX

LBS (KGS)

ACC’Y XXXX LBS

(KGS)

MTN DELAY XS

OVR DBNCE XS

OVR HOLD XS

X.XXXX #1 ZERO +X.XXXX mV #2 GAIN X.XXXX #2 ZERO +X.XXXX mV #3 GAIN X.XXXX #3ZERO +X.XXXX mV #4 GAIN X.XXXX #4 ZERO +X.XXXX mV EX GAIN X.XXXX TEMP OFFS +/- XXX.X

Description 4069LE 3369LE 500RTS 260MRT

Displays/adjusts the overload limit for this

AWP

Displays/adjusts a de-rating for

Accessories

Displays/adjusts the delay between motion

ceasing and evaluation of overload

Displays/adjusts the de-bounce delay

before an overload

Displays/adjusts the minimum delay

before an overload can be released.

Displays/calibrates the LSS Module analog channel gain Displays/calibrates the LSS Module analog channel offset. Displays/calibrates the LSS Module analog channel gain Displays/calibrates the LSS Module analog channel offset Displays/calibrates the LSS Module analog channel gain Displays/calibrates the LSS Module analog channel offset Displays/calibrates the LSS Module analog channel gain Displays/calibrates the LSS Module analog channel offset Displays/calibrates the LSS Module excitation measurement gain Displays/calibrates the LSS Module internal temp sensor

THE SETTINGS UNDER THE FACTORY MENU OPTION ARE UNIQUE TO EACH MODULE. THESE SETTINGS ARE NOT TO BE ALTERED. IN THE EVENT THAT THESE SETTINGS ARE ALTERED, CONTACT JLG WITH THE SERIAL NUMBER OF THE MODULE.

Extensions-

2628 LBS

(1192 KGS)

Single or

550 LBS

(378 KGS)

0 LBS

(0KGS)

2 SEC 2 SEC 2 SEC 2 SEC

3 SEC 3 SEC 3 SEC 3 SEC

5 SEC 5 SEC 5 SEC 5 SEC

1042 LBS

(473 KGS)

0 LBS

(0KGS)

Dual

Extensions

2083 LBS

(945 KGS)

MegaDeck-

1574 LBS

(714 KGS)

0 LBS

(0KGS)

1320 LBS

(599 KGS)

0 LBS

(0KGS)

3124288 – JLG Lift – 2-5

SECTION 2 - OPERATION - (LE, MRT, RTS)

2.5 MACHINE SETUP MENU (LE, MRT & RTS)

The Machine Setup Menu is used to configure the Load Sensing System for application on a particular JLG model, and select the desired force units (i.e. pounds or kilograms). In addition, the technician can trigger the LSS Module to restore Defaults to all Personalities Parameters by changing the MODEL to any other selection, and then re-selecting proper model.

Note that Diagnostics and Personalities Menus change based on MODEL Parameter (some displays are suppressed).

To access the Machine Setup Menu, use the LEFT and RIGHT Arrow keys to select MACHINE SETUP from the Top Level Menu. Press the ENTER key to view the menu. Press the LEFT and RIGHT Arrow keys to view the displays.

The following table details the structure of the Machine Setup Menu, and describes the meaning of each parameter.

Table 2-4. Machine Setup Menu

Parameter

(Displayed on

Analyzer 2

Line)

MODEL:

UNITS:

=BOOM LIFT =4069LE =3369LE =500RTS =260MRT =Scissor

=LBS =Kg

Analyzer 2

Parameter Value

(Displayed on

Line)

Description

Displays/adjusts Model Selection. Must be set to proper model for this application. (Scissor available after software V7.00)

Displays/adjusts global force units

2.6 CALIBRATION MENU (LE, MRT & RTS)

The Calibration Menu is used to zero the Empty Platform weight.

To access the Calibration Menu, use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu. Press the ENTER key to view the menu.

NOTE: The Calibration Menu is not available in Access

Level 2.

Upon entry to the Calibration Menu, the LSS Module shall communicate to the Analyzer:

CALIBRATE:

YES:ENTER, NO:ESC

Pressing the ESC key will return the user to the top level menu and not disturb the prior calibration information.

2-6 – JLG Lift – 3124288

SECTION 2 - OPERATION - (LE, MRT, RTS)

Pressing the ENTER key will confirm that the platform is empty (except for factory-installed options outside the Rated Load). The LSS Module will calculate the total of all load cell readings and ensure that the total is greater than minimum calibration value, but less than maximum calibration value. If successful, the Analyzer will show the following:

If the empty platform weight is less than minimum calibration value, the calibration attempt will be unsuccessful and the Analyzer will show the following:

CALIBRATE:

< MIN CAL

CALIBRATE:

COMPLETE

Table 2-5. Calibration Values

MODELS 4069LE 3969LE 500RTS 260MRT

Minimum Cali-

bration Value

Maximum Cali-

bration Value

850 lb

(385 kg)

1425 lb

(646 kg)

850 lb

(385 kg)

1425 lb

(646 kg)

110 0 l b

(499 kg)

2950 lb

(1338 kg)

(340 kg)

1250 lb

(567 kg)

If the empty platform weight is greater than maximum calibration value, the calibration attempt will be unsuccessful and the Analyzer will show the following:

750 lb

CALIBRATE:

> MAX CAL

3124288 – JLG Lift – 2-7

SECTION 2 - OPERATION - (LE, MRT, RTS)

(

)

DIAGNOSTICS PERSONALI TIES MACHINE SETUP

FACTORY

MODEL = BOOMLI FT

4069LE, 3369LE, 500RTS,

260MRT, SCISSOR

YES: ENTER, NO:ESC

UNITS = LBS/KG

CALI BRATIONS

OWR HOLD=0,

10, 25, 50, 100,

250, 500MS;1,2

3,5, 10 secr et ar y

ACCY XXXX

LBS, KG

VERSIONS

#2 GAIN X.XXXX

#1 ZERO +/- X.XXXX

#1 GAIN X.XXXX

#2 ZERO +/- X.XXXX

#1 ZERO +/- X.XXXX

#1 GAIN X.XXXX

#3 ZERO +/- X.XXXX

#3 GAIN X.XXXX

#4 ZERO +/- X.XXXX

#4 GAIN X.XXXX

TEMP OFFS +/- XXX.XC

EXCITE GA

IN X.XXXX

OWR DENCE=0,

10, 25, 50, 100,

250, 500MS;1,2

3,5, 10 secr et ary

MTN DLY =0,

10, 25, 50, 100,

250, 500MS;1,2

3,5, 10 secr et ar y

OVERLD XXXX

LBS, KG

Figure 2-1. Module Analyzer Flow Chart

2-8 – JLG Lift – 3124288

SECTION 2 - OPERATION - (LE, MRT, RTS)

2.7 JLG WORKSTATION IN THE SKY™ ACCESSORIES

The Load Sensing System must be configured for proper operation with JLG Sky™ Accessories. Calibration of the Load Sensing System can be performed with the Accessory mounted in the platform.

A platform-mounted accessory slightly reduces the amount of load that can be carried before the vehicle becomes overloaded. This extra load must be accounted for to enable the accessory to be mounted during Calibration.

A De-Rating is provided for JLG Sky Accessories via decal

and/or the JLG Workstation in the 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 that of the Easi-Cladder™ with a DeRating of 300 lbs (136 kg) mounted on a 500RTS. Without De-Rating, the Load Sensing System will declare on Overload at 2750 lb (1247 kg), which is 110% of its 2500 lb (1134 kg) rated Load. When the De-Rating for Easi-Cladder™ is entered into the ACC’Y Personality, the LSS will declare Overload 300 lb (136 kg) earlier (2450 lb or 1111 kg).

Accessory Man-

Table 2-6. LSS Module Guidelines

PERSONALITY SETTING

ACC’Y 300 lb (136 kg)

Procedurally, the Accessory should be mounted to the platform and the LSS Module’s ACC’Y Personality should be set using the guidelines above. Calibration should be performed as outlined in this manual. During Testing & Evaluation, it should be noted that the LSS will declare Overload with less platform load (by the amount of the DeRating).

3124288 – JLG Lift – 2-9

SECTION 2 - OPERATION - (LE, MRT, RTS)

NOTES:

2-10 – JLG Lift – 3124288

SECTION 3 - OPERATION - (ES, RT)

SECTION 3. OPERATION - (ES, RT)

3.1 CONNECTING THE JLG CONTROL SYSTEM ANALYZER (ES & RT)

1. Connect the cable supplied with the Analyzer to the

host control system located at the ground controlstation on both the ES and the RT models. There is also an alternate connection on the under side of the platform control station on the RT. Connect the remaining end of the cable to the analyzer.

NOTE: The cable has a four-pin connector at each end of

the cable; The cable cannot be connected backwards.

2. Power-up the Control System by turning the key to the Platform or Ground position and pulling both emergency stop buttons.

Table 3-1. LSS Fault Codes (LE, MRT and RTS)

Help/Logged Message

PLATFORM OVERLOADE D

BATTERY TOO HIGH 4-4 Incoming Supply Voltage >34.0 Vdc. The control system’s battery voltage is too high. This may be due to over-charg-

BATT TOO LOW 4-4 Incoming Supply Voltage <9.0 Vdc. The control system’s battery voltage is too low due to excessive electrical load or

CANBUS FAILURE: LSS MODULE

C EL L #1 E R RO R 8 -1 C el l #1 ’ s Br i dg e <2 V, >3 V, o r c o ul d no t r ea d Ce ll #1’s Internal Memory. This situation indicates damage to the sen-

C EL L #2 E R RO R 8 -2 C el l #2 ’ s Br i dg e <2 V, >3 V, o r c o ul d no t r ea d Ce ll #2’s Internal Memory. This situation indicates damage to the sen-

C EL L #3 E R RO R 8 -3 C el l #3 ’ s Br i dg e <2 V, >3 V, o r c o ul d no t r ea d Ce ll #3’s Internal Memory. This situation indicates damage to the sen-

C EL L #4 E R RO R 8 -4 C el l #4 ’ s Br i dg e <2 V, >3 V, o r c o ul d no t r ea d Ce ll #4’s Internal Memory. This situation indicates damage to the sen-

WATCHDOG RST 9-1 Microprocessor’s Watchdog Timer Triggered. This is an indication that the LSS Module has been exposed to exces-

EEPROM ERROR 9-2 Memory used to retain Personality/Machine Setup/Calibration has been corrupted and must be reset by verifying all

LSS NOT CALIBRATED 9-3 Calibration has not been successfully completed. A new LSS Module will display this message until properly cali-

LSS INTERNAL ERROR

- PIN EXCITATION

LSS INTERNAL ERROR

- DRDY MISSING FROM A/D

Flash Code

2-5 The platform load measured at the Load Sensing System is excessive. Functions from the platform control are pre-

vented, and functions from the ground control may be prevented, depending on machine.

ing or improper charger operation.

discharge. This may compromise ability to predict weight. Recharge batteries or check for damaged batteries.

6-6 The control system failed to receive messages from the LSS Module. Check wiring at the LSS Module and along scis-

sor arms leading up to platform.

sor or its wiring.

sive electrical noise, or has experienced a hardware difficulty.

entries and re-calibrating. After resolution, re-cycle power to clear difficulty.

brated.

9-9 Pin excitation <4.25 V. The sensors may be excessively loading the excitation supply, or the LSS Module may have

hardware difficulty.

9-9 DRDY Interrupt from LSS Module’s A/D conver ter missing. This may indicate an LSS Module hardware difficulty.

3.2 HELP MENU & FAULT CODES (ES & RT)

When accessing the Help Menu, the JLG Analyzer will display EVERYTHING OK if the platform is not overloaded and no difficulties are detected. Otherwise, the JLG Analyzer will display OVERLOADED.

Description of Situation

3124288 – JLG Lift – 3-1

SECTION 3 - OPERATION - (ES, RT)

3.3 DIAGNOSTIC MENU (ES & RT)

The Diagnostic Load Menu is another troubleshooting tool for the Load Sensing System. Sensor and status information is presented in real-time for the technician.

To access the Diagnostic Menu, use the LEFT and RIGHT Arrow keys to select DIAGNOSTICS from the Top Level Menu. Press the ENTER key to select the menu.

Table 3-2. Diagnostic Menu Descriptions (ES & RT)

Diagnostics Menu

(Displayed on Analyzer 1

LOAD:

Parameter (Displayed

Line)

on Analyzer 2

PLTLOAD +XXXX Kg Displays (Total Measured Force – Empty Platform

PLTGROS +

OVERLOADED? Yes / N o Displays Current LSS Module Over load Status

CELL 1 +

CELL 2 +

CELL 3 +

CELL 4 +XXXX Kg Displays Calibrated Cell Reading in kilograms

ANALYZER VX.XXXX Displays Analyzer Software Version

Line)

NOTE: The Diagnostic, Load menu is not available when the

LSS is not enabled. (Machine Setup, Load is set to 0=Not Installed

Press the LEFT and RIGHT Arrow keys to view the load sub-menus and press the enter key. Once in the load submenu, press the LEFT and RIGHT arrow keys to view the various displays.

The table below details the structure of the Diagnostic, Load Menu, and describes the meaning of each piece of information presented.

Parameter Value

(Displayed on Analyzer 2

Line)

XXXX Kg D i sp l ay s Tot a l Me a su r ed F or c e (S u m o f Pi n s 1 t h r u 4

XXXX Kg Displays Calibrated Cell Reading in kilograms

Calibration), in kilograms

LOA D) in k ilo gr ams

Description

3.4 PERSONALITIES (ES & RT)

The following parameter in the PERSONALITIES, LOAD menu adjust performance of the LSS. All adjustments must be made in Access Level 1 (33271).

Table 3-3. Personalities (ES & RT)

Submenu (Displayed on

analyzer1st LIne)

LOAD: ACC’Y XXXX KG

Parameter (Displayed on

REFER TO JLG WORKSTATION IN THE SKY™ ACCESSORIES IN THIS SECTION WITH REGARD TO SETTING THE ACCY PERSONALITIES.

analyzer 2nd line)

OVR DBNCE 3 S

OVR HOLD 5 S

Description

Displays/adjusts a derating for accessories

Displays/ adjusts the debounce delay before an overload

Displays/adjusts the minimum delay before an overload can be released.

3-2 – JLG Lift – 3124288

SECTION 3 - OPERATION - (ES, RT)

3.5 MACHINE SETUP MENU (ES & RT)

The LOAD submenu within the machine setup menu is used to configure the LSS. To access the Machine Setup, Load menu, use the Left and Right arrow keys to select MACHINE SETUP from the Top Level Menu. Press the ENTER key to select the menu. Press the Left and Right arrow keys to select LOAD from the MACHINE SETUP menu. Press the Enter key to view the submenu.

The following table details the structure of the load submenu and describes the meaning of the parameter.

Table 3-4. Machine Setup

Submenu

(Displayed on

analyzer1st LIne)

LOAD:

Parameter

(Displayed on

analyzer 2nd line)

0 = NOT INSTALLED

1 = CUTOUT PLT

2 =CUTOUT ALL

Description

Displays/adjusts the

LSS Module

3.6 CALIBRATION MENU (ES & RT)

The Load submenu within the Calibration Menu is used to zero the Empty Platform weight.

To access the Calibration Load Menu, use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu. Press the ENTER key to select the menu. Press the LEFT and RIGHT arrow keys to select LOAD from the CALIBRATION menu. Press the ENTER key to view the submenu.

NOTE: The Calibration Menu is not available in Access

Level 2.

Upon entry to the Calibration, Load Menu, the analyzer will display:

CALIBRATE:

YES:ENTER, NO:ESC

Pressing the ESC key will return the user to the top level menu and not disturb the prior calibration information.

3124288 – JLG Lift – 3-3

SECTION 3 - OPERATION - (ES, RT)

CALIBRATE:

COMPLETE

If the empty platform weight is less than minimum calibration value, the calibration attempt will be unsuccessful and the Analyzer will show the following:

CALIBRATE:

< MIN CAL

If the empty platform weight is greater than maximum calibration value, the calibration attempt will be unsuccessful and the Analyzer will show the following:

Table 3-5. Calibration Values

MODELS ES RT

Minimum Calibration Value

Maximum Calibration Value

45 KG

(99 LB)

275 KG

(606 LB)

225 KG

(496 LB)

1020KG

(2249 LB)

CALIBRATE:

> MAX CAL

3-4 – JLG Lift – 3124288

SECTION 3 - OPERATION - (ES, RT)

(

)

DIAGNOSTICS PERSONALI TIES MACHINE SETUP

FACTORY

MODEL = BOOMLI FT

4069LE, 3369LE, 500RTS,

260MRT, SCISSOR

YES: ENTER, NO:ESC

UNITS = LBS/KG

CALI BRATIONS

OWR HOLD=0,

10, 25, 50, 100,

250, 500MS;1,2

3,5, 10 secr et ar y

ACCY XXXX

LBS, KG

VERSIONS

#2 GAIN X.XXXX

#1 ZERO +/- X.XXXX

#1 GAIN X.XXXX

#2 ZERO +/- X.XXXX

#1 ZERO +/- X.XXXX

#1 GAIN X.XXXX

#3 ZERO +/- X.XXXX

#3 GAIN X.XXXX

#4 ZERO +/- X.XXXX

#4 GAIN X.XXXX

TEMP OFFS +/- XXX.XC

EXCITE GA

IN X.XXXX

OWR DENCE=0,

10, 25, 50, 100,

250, 500MS;1,2

3,5, 10 secr et ary

MTN DLY =0,

10, 25, 50, 100,

250, 500MS;1,2

3,5, 10 secr et ar y

OVERLD XXXX

LBS, KG

Figure 3-1. Module Analyzer Flow Chart

3124288 – JLG Lift – 3-5

SECTION 3 - OPERATION - (ES, RT)

NOTES:

3-6 – JLG Lift – 3124288

SECTION 4. OPERATION - (RS)

SECTION 4 - OPERATION - (RS)

4.1 CONNECTING THE JLG CONTROL SYSTEM ANALYZER (RS)

1. Remove the compartment panel on the ground con-

trol side of the machine.

2. Disconnect the 4 pin connector which provides power and information to the MDI Display.

3. Connect the cable supplied with the Analyzer to the mating 4 pin connector that was just disconnected.

NOTE: The cable has a four-pin connector at each end of

the cable; The cable cannot be connected backwards.

4. Power-up the Control System by turning the key to the Ground Control position and pull the Ground emergency stop button.

Table 4-1. LSS Fault Codes (RS ONLY)

HELP/LOGGED MESSAGE

Everything OK LED ON The "Normal" Help Message

PLATFORM OVERLOADED 2-5 While the Load Sensing System is enabled, the Platform Load measured by the Load Sensing System is

CANBUS FAILURE - LSS ANGLE SENSOR

LSS PRESSURE SENSOR DISAGREEMENT

LSS ANGLE SENSOR - DIRECTION DISAGREEMENT

LSS ANGLE SENSOR OUT OF RANGE HIGH

LSS ANGLE SENSOR OUT OF RANGE LOW

LSS ANGLE SENSOR HAS NOT BEEN CALIBRATED

FLASH

CODE

excessive. Functions from Platform Control are prevented, and functions from Ground Control may be prevented, depending on machine configuration (Markets other than Japan). For the Japanese Market, only Lift Up is prevented and Drive (at creep speed) is allowed in the stowed position.

6-6 The Control System Failed to receive messages from the Angle Sensor. Check wiring to the Angle Sensor.

8-2 Pressure Sensor 1 and Pressure Sensor 2 do not agree. The system shall assume the machine is overloaded

until the sensors agree. Using the Analyzer LOAD submenu under DIAGNOSTICS check PRES1 and PRES2 readings. They must agree within 75 PSI. With the safety prop engaged check to ensure that the appropriate voltage is being supplied to both sensors and that the wiring and connections are intact. The voltage between pins A and B should read +5V +/- 0.5V with the machine turned on. If the voltage supplied is correct, replace both transducers.

8-2 The Angle sensors change in reading does not agree with the direction of machine motion (lift up).This indi-

cates that the direction of movement of the platform does not agree with the angle sensors change in output. Ensure that the angle sensor is installed properly and that the lever arm is not damaged.

8-2 The Angle Sensor's reading when the machine is at maximum elevation does not fall within the high end

acceptable range. The Angle Sensors reading must be less than or equal to 245 counts at maximum elevation. Ensure that the Angle Sensor is mounted properly.

8-2 The Angle Sensor's reading when the machine is stowed does not fall within the low end acceptable range.

The Angle Sensors reading must be greater than or equal to 5 counts with the platform stowed. Ensure that the Angle Sensor is mounted properly.

8-2 The Angle Sensor has never been calibrated and the control system assumes that the platform is overloaded.

Calibrate the Angle Sensor using the CALIBRAT ION: ANGLE submenu to clear the message.

4.2 HELP MENU & FAULT CODES (RS)

When accessing the Help Menu, the JLG Analyzer will display EVERYTHING OK if the platform is not overloaded and no difficulties are detected. Otherwise, the JLG Analyzer will display OVERLOADED.

DESCRIPTION OF SITUATION

3124288 – JLG Lift – 4-1

SECTION 4 - OPERATION - (RS)

4.3 DIAGNOSTIC MENU (RS)

The Diagnostic Load and Angle menu's are another troubleshooting tool for the Load Sensing System. Sensor and status information is presented in real-time for the technician.

To access the Diagnostic Menu, use the LEFT and RIGHT Arrow keys to select DIAGNOSTICS from the Top Level Menu. Press the ENTER key to select the menu.

NOTE: The Diagnostic Load and Angle menu's are not avail-

able when the LSS is not enabled. (Machine Setup, Load is set to 0=Not Installed

Press the LEFT and RIGHT arrow keys to view the load and angle sub-menu and press the enter key. Once in the load and angle submenu, press the LEFT and RIGHT arrow keys to view the various displays.

The table below details the structure of the Diagnostic, Load Menu and Angle Menu, and describes the meaning of each piece of information presented.

Table 4-2. Diagnostic Menu Descriptions (RS)

DIAGNOSTICS MENU

(Displayed on Analyzer 1

Line)

PARAMETER

(Displayed on Analyzer

Line)

PARAMETER VALUE

(Displayed on Analyzer 2

Line)

DESCRIPTION

LOAD: OVERLOADED? Yes/No Displays the current LSS state.

PRES1 xxxxPSI Displays the actual pressure reading from Pres-

sure Transducer #1.

PRES2 xxxxPSI Displays the actual pressure reading from Pres-

sure Transducer #2.

LOAD: PRES DIF P1-P2 xxxxPSI Displays the absolute pressure difference

between transducer 1 and transducer 2. PRES DIF = ABSOLUTE(PRES1 - PRES2).

LOAD: PRES DIF OVLD-P1 xxxxPSI Displays the pressure difference between Lift Up

or Lift Down Pressure Overload Limits (depending on motion) and Actual Pressure. M AR G IN = L if t U p P r es s ur e Ov e r lo a d L i mi t - P RE S 1 o r M AR G IN = Li f t Do w n Pr e ss u re O ve r load Limit - PRES1.

LOAD: TOCLEAROVLD PRES xxxxPSI Displays the amount of pressure that must be

reduced before the overload condition is resolved. XXX = PRES1 - (OVRPRES - PRESREDUCE). When an overload condition does not exist this value shall be 0.

ANGLE: MINANGLE xxx Displays the angle sensors MINANGLE (stowed)

value based on angle sensor calibration.

MAXANGLE xxx Displays the angle sensors MAXANGLE (max ele-

vation) value based on angle sensor calibration.

ANGLERANGE xxx Displays the difference between MAXANGLE and

MINANGLE. ANGLERANGE = MAXANGLE - MINANGLE.

ANGLE xxx Displays the actual angle sensor count value at all

times.

4-2 – JLG Lift – 3124288

SECTION 4 - OPERATION - (RS)

CAL ANGLE:

YES:ENTER NO:ESC

4.4 PERSONALITIES MENU (RS)

The following parameter in the PERSONALITIES, LOAD menu adjust performance of the LSS. All adjustments must be made in Access Level 1 (33271).

Table 4-3. Personalities Menu Description (RS)

SUBMENU

(Displayed on

Analyzer 1st line)

LOAD: OVR DBNCE 0.3S Displays/Adjusts the

PAR AMET ER

(Displayed on

Analyzer 2nd Line)

OVR HOLD 5.0S Displays/Adjusts the

DESCRIPTION

debounce delay for an overload.

minimum delay before an overload can be resolved.

4.5 CALIBRATION MENU (RS)

NOTE: The Load Sensing System cannot be calibrated with-

out first calibrating the machines Angle Sensor.

Angle Sensor Calibration (RS Only)

To access the Calibration Angle Menu, use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu. Press the ENTER key to select the menu.

Press the LEFT and RIGHT arrow keys to select ANGLE from the CALIBRATION menu. Press the ENTER key to view the submenu.

Should the Analyzer read CAL ANGLE:FAIL at any time during the calibration procedure, reference the table below for the failure listed by the Analyzer.

NOTE: The Calibration Menu is not available in Access

Level 2.

Upon entry to the Calibration, ANGLE Menu, the analyzer

will display:

CAL ANGLE:

YES:ENTER, NO:ESC

Pressing the ESC key will return the user to the top level menu and not disturb the prior calibration information.

3124288 – JLG Lift – 4-3

SECTION 4 - OPERATION - (RS)

CAL ANGLE:

LIFT TO MAX

CAL ANGLE:

LOWER TO STOWED

CAL ANGLE:

COMPLETE!

Pressing the Enter key will request that the technician engage lift up until the platform has reached maximum height:

CAL ANGLE:

LIFT TO MAX

If the Angle Sensor's reading at maximum height is acceptable the Control System will record the sensors value and Analyzer will display the following.

If the Angle Sensors range from stowed to maximum height is acceptable the Analyzer will display the following:

CAL ANGLE:

COMPLETE!

CAL ANGLE:

LOWER TO STOWED

4-4 – JLG Lift – 3124288

SECTION 4 - OPERATION - (RS)

CAL LOAD:

YES: ENTER NO: ESC

Table 4-4. Angle Sensor Calibration Failure Troubleshooting (RS Only)

ANGLE SENSOR CALIBRATION FAILURE

(Displayed on Analyzer 2nd Line)

MAX NOT IN RANGE The Angle Sensors upper limit is not accept-

able. It must fall within +/- 35 counts of 210 counts.

MAXANGLE TOO HIGH The MAXANGLE value was greater than 245

counts. The MAXANGLE value mu st be a number less than or equal to 245.

LOW NOT IN RANGE The Angle Sensors lower limit is not acceptable.

It must fall within +/- 35 counts of 40 counts.

MINANGLE TOO LOW The MINANGLE value was less than 5 counts.

The MINANGLE value must be a number more t ha n or e q ua l to 5 .

INVALID RANGE The sensors range from the platform stowed

position to the platform's maximum elevation position was not acceptable.

CAL FAIL! The technician has pressed ESC on the Ana-

lyzer during the calibration routine

4.6 LOAD SENSING SYSTEM CALIBRATION (RS ONLY)

To access the Calibration Load Menu, use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu. Press the ENTER key to select the menu.

Press the LEFT and RIGHT arrow keys to select LOAD from the CALIBRATION menu. Press the ENTER key to view the submenu. Should the Analyzer read CAL LOAD:FAIL at any time during the calibration procedure, reference the table below for the failure listed by the Analyzer.

DESCRIPTION CHECK

Upon entry to the Calibration, LOAD Menu, the analyzer will display:

• Check the Angle Sensor to ensure it is installed properly.

• Ensure that the Angle Sensors lever arm is installed properly.

• Check the Angle Sensor to ensure it is installed properly.

• Ensure that the Angle Sensors lever arm is installed properly.

• Check the Angle Sensor to ensure it is installed properly.

• Ensure that the Angle Sensors lever arm is installed properly.

• Check the Angle Sensor to ensure it is installed properly.

• Ensure that the Angle Sensors lever arm is installed properly.

• "Check the Angle Sensor to ensure it is installed properly.

• "Ensure that the Angle Sensors lever arm is installed properly.

NOTE: The Calibration Menu is not available in Access

Level 2.

PRIOR TO LOAD SENSING SYSTEM CALIBRATION ENSURE THAT THE MACHINE HAS BEEN PLACED ON LEVEL GROUND, THE HYDRAULIC FLUID IS WITHIN THE ACCEPTABLE RANGE, THE TEMPERATURE IS GREATER THAN 32 DEGREES F, AND THE BATTERIES ARE FULLY CHARGED.

CAL LOAD:

YES:ENTER, NO:ESC

Pressing the ESC key at any time will return the user to the top level menu and not disturb the prior calibration information.

Pressing the Enter key will ensure that appropriate Calibration Weight, 110% rated load, has been placed in the

3124288 – JLG Lift – 4-5

SECTION 4 - OPERATION - (RS)

CAL LOAD:

110% LOAD CENTER?

CAL LOAD:

LIFT TO MAX ELEV

CAL LOAD:

LOWER TO STOWED

CAL LOAD: COMPLETE!

center of the platform. The Analyzer will display the following.

CAL LOAD:

110%LOAD,CENTER?

Pressing the Enter Key again will make the Analyzer display the following which means engage lift up from the ground panel until the platform reaches maximum elevation.

Pressing the Enter key again will make the Analyzer display the following which means engage lift down until the platform becomes stowed.

CAL LOAD:

LOWER TO STOWED

If the Load Calibration is successful the Analyzer will display the following.

CAL LOAD:

COMPLETE!

LIFT TO MAX ELEV

4-6 – JLG Lift – 3124288

SECTION 4 - OPERATION - (RS)

Table 4-5. Load Calibration Failure Troubleshooting (RS Only)

LOAD CALIBRATION FAILURE

(Displayed on Analyzer 2nd Line)

NOT IN GND MODE The machine is not in Ground Mode. • Set the key switch so that the machine is in

CAL ANGLE The Angle Sensor has not been calibrated. • Navigate to the Calibrations menu and

PLAT NOT STOWED The machines platform is not stowed. • Ensure that the platform is stowed and per-

MOTION STOPPED The platform stopped moving during calibra-

tion.

CAL FAIL The technician has pressed ESC on the Ana-

lyzer during the calibration routine.

DESCRIPTION CHECK

Ground Mode.

• The machine must be in ground Mode for Load calibration.

enter the Angle submenu to perform Angle Sensor calibration.

• The Angle sensor must be calibrated before Load calibration can occur.

form the Load calibration again.

•The technician let go of the lift up switch before the machine reached maximum elevation during "CAL LOAD: LIFT TO MAX ELEV".

3124288 – JLG Lift – 4-7

SECTION 4 - OPERATION - (RS)

NOTES:

4-8 – JLG Lift – 3124288

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

465

NOTE ORI ENTATION OF PIN ARROW,

POINTED AWAY FROM PLATFORM

1. Load Cell (Typical 4 Corners)

2. System Interface - Power & Digital - J1

3. System Interface Communication - J2

4. Indicator Light

5. Rear Right Load Cell - J8

6. Rear Left Load Cell - J7

7. Front Right Load Cell - J6

8. Front Left Load Cell - J5

Figure 5-1. Load Sense Module

SECTION 5. SERVICE - (LE, MRT, RTS, ES, RT)

5.1 DESCRIPTION

The system consists of the LSS Module, four Shear Pin Load Cells (sensors), Wire Harness, and various brackets and fasteners. The LSS Module is mounted beneath the platform on a bracket. The Shear Pin Load Cells mount

between the platform and the arm structure in such a way that all support force for the platform is applied through them (for measurement). The four Shear Pin Load Cells plug directly into the LSS Module. The Wire Harness connects the LSS Module to the Host Control System.

3124288 – JLG Lift – 5-1

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

5.2 CALIBRATION

Procedure

1. Plug the JLG Analyzer into the LSS Module on the LE, MRT and RTS or the Host Control System on the ES and RT and enter the Access Level 1 Password. Do not confuse the Host Control System and LSS Module’s Analyzer Connections. Proceed to the ACCESS LEVEL menu and enter the Access Level 1 Password (33271).

2. Park the vehicle on a level surface. should be fully stowed and level within ± 5° (both directions).

3. Configure the LSS Module for the proper model and Desired Units. On LE, MRT and RTS, proceed to the LSS Module’s MACHINE SETUP, MODEL sub-menu and select “MODEL=4069LE, 3369LE, 500RTS, or 260MRT”. Press the RIGHT ARROW to view the Units Selection. Select “UNITS=LBS” for platform load measurement in Pounds, and “UNITS=KG” for measurement in Kilograms.

EARLY RT’S REQUIRE A CONFIGURATION TO THE LSS MODULE. PLUG THE JLG ANALYZER INTO THE MODULE’S CONNECTION BENEATH THE DECKAND ENTER THE ACCESS LEVEL 1 PASSWORD (33271). UNDER MACHINE SETUP ENSURE THAT MODEL=260MRT.

4. Remove everything except JLG Accessories from the Platform. Empty the platform to allow the Load Sensing System to record its weight during calibration. All tools, debris, and customer-installed devices shall be removed. Permanently-fixed JLG Accessories shall remain and their contribution toward Rated Load will be accounted for in the next step.

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. 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).

The platform

The

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.

Proceed

Te s t i n g & E v a l u a t 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 (LE, MRT and RTS) or the Host Control System (ES and RT).

2. Park the vehicle on a level surface. should be fully stowed and level within ± 5° (both directions).

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 40lbs (18kg) (max PLTLOAD reading – min PLTLOAD reading).

15lbs (± 7kg). Further, the reading

The platform

Proceed to the

The techni-

5-2 – JLG Lift – 3124288

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

5. Confirm Host Control System Warnings and Interlocks. Using the vehicle’s keyswitch, select Platform Mode and power-up. Start the vehicle’s engine (If equipped) and ensure that all controls are functional and the Load Sensing System’s Overload Visual and Audible Warnings are not active. Simulate an Overload by unplugging the Shear Pin Load Cell connected to J5 on the LSS Module. The Overload Visual Warning should flash, and the Audible Warning (at Platform and Ground) should sound for 5 seconds On, and 2 seconds Off. With the engine running (If equipped), all platform control should be prevented. Cycle the Platform EMS to stop the engine and then power-up again. The Overload Visual and Audible Warning should continue. Install the disconnected Shear Pin Load Cell back in J5 on the LSS Module. The Overload Visual and Audible Warnings should cease and normal control function should return. Switch the vehicle’s keyswitch to Ground Mode and repeat the above procedure. The Overload Visual Warning at the Ground Controls should flash, and the Audible Warning (at Platform and Ground) should sound for 5 seconds On, 2 seconds Off. However, the controls should remain functional when using the engine (if the Host Controls System’s MACHINE SETUP, LOAD is set to “2=CUTOUT PLT”. If set to “3=CUTOUT ALL”, then Ground Controls will be prevented when using the platform). Re-fit the Shear Pin Load Cell connector to J5 on the LSS Module and carefully tighten by hand, and then with a small pair of locking pliers to seat the O-ring seal.

6. Confirm Load Sensing System Performance with Calibrated Weights. Operate the vehicle from Ground Control and place the platform in the fully stowed position for safety. Place 120% of the machines rated load in the center of the platform and ensure that the overload visual and audible warnings are active. Reduce the platform load to 100% rated load and ensure that the warnings are not active. For vehicles with multiple capacities, evaluate each operating mode with the proper rated load.

3124288 – JLG Lift – 5-3

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

5.3 TROUBLESHOOTING

The following tables are furnished to provide possible resolutions for common difficulties. Difficulties are classified

Table 5-1. 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.

as General, Calibration, Measurement Performance, and Host System Functionality.

5-4 – JLG Lift – 3124288

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 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Table 5-2. LSS Troubleshooting Chart - Calibration

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

1. The platform is being supported by something other than the four Shear Pin Load Cells. This includes binding between the slide block/spacer bushing/arm tube assembly (bushing should be free enough to rotate by hand). For proper operation, the platform’s entire weight must be transferred through the Shear Pin Load Cells and into the arm support structure for an accurate calibration.

2. The wrong Model Selection was made under the LSS Module’s MACHINE SETUP, MODEL. This should be set to the proper MODEL (4069LE, 3369LE, 500RTS, 260MRT or SCISSOR). Improper selection may lead the LSS Module to expect different empty platform weights.

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

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 (4069LE, 3369LE, 500RTS, or 260MRT). Improper selection may lead the LSS Module to expect different empty platform weights.

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

3124288 – JLG Lift – 5-5

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Table 5-3. LSS Troubleshooting Chart - Measurement Performance

Difficulty Possible Resolution

Empty Platform Weight (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 40lbs (18kg) for an evaluation using the technician’s weight, and + Rated Load when using calibrated weights.

15lbs (±7kg) of zero.

5% of

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

1. One of the Shear Pin 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 Pin 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 Pin 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 Pin Load Cell since the cordset is not serviceable (connector is molded for moisture resistance; cordset is soldered into sensor beneath welded stainless steel cover). If damage to the sensors extension cordset is found, unplug both ends and fit a replacement.

3. One of the Shear Pin Load Cells was not assembled properly during installation. Examine each sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and determine if the readings are reasonable. It is often helpful to apply slight downward pressure above the sensor being examined and observe that its output increases (increasing force measurement; decreasing means the sensor is mounted upside-down). Compare the order of assembly to the detail on the Installation Drawing and ensure that the only contact between the platform and the support is through the sensor bodies (nothing else touches except wires). Re-assemble according to print if necessary.

(continued)

5-6 – JLG Lift – 3124288

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Table 5-3. LSS Troubleshooting Chart - Measurement Performance

Difficulty Possible Resolution

4. Damage to the platform or arm structure has occurred or one of the components is out-of-tolerance.Twists in the platform, for instance, will cause huge off-axis forces to be applied to the Shear Pin Load Cells, disturbing their primary measurement axis readings. If Lift Up / Down is noisy or not smooth, examine this issue thoroughly. Resolution is to replace the damaged or faulty component. Watch for Shear Pin Load Cell damage (yield) as a result of this difficulty.

5. One of the Shear Pin Load Cells is contaminated by debris or moisture. Examine each sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and determine if the readings are reasonable and stable (not changing by more than + Lack of measurement stability is a key indication of contamination. Unplug the appropriate connector (J5 is CELL 1, J6 is CELL 2, J7 is CELL 3, and J8 is CELL 4) and inspect for dirt or moisture. Look carefully into the female connector on the sensor’s cordset for evidence of contamination. Debris should be brushed away with a soft bristle brush (do not introduce any cleaners as they will leave conductive residue). Moisture should be allowed to evaporate or accelerated with a heat-gun (use low heat and be carefully to not melt connector materials). Moisture intrusion into the molded portion of the connector (capillary action into the wire bundle) or the Shear Pin Load Cell itself will require replacement of the sensor.

6. One of the Shear Pin Load Cells has been mechanically damaged (yielded). Any Shear Pin Load Cell that is physically deformed or has damage to one of the stainless steel covers should be replaced immediately. It is also possible to have invisible mechanical damage resulting from an extreme overload (>4200lbs [>1900kg] for

1.25 in diam.; >5700 lbs or 2600 KG for 2 inch diam.). This can be detected by supporting the platform with an overhead crane and by removing the suspect sensor (no weight resting on the Shear Pin Load Cell). Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and observe whether the unloaded sensors read with + Replace sensors that read excessive force when physically unloaded.

7. The LSS Module is suspect. Interchange the Shear Pin Load Cell connections (J5J8) and observe the results via the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD displays and observe the readings. If the problem seems to remain with a particular sensor, carefully re-examine the issues above. If the problems seems to remain with a particular LSS Module channel, substitute another module.

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

15lbs (±7kg) of zero (individually).

3124288 – JLG Lift – 5-7

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Table 5-4. LSS Troubleshooting Chart - Host System Functionality

Difficulty Possible Resolution

The Visual and Audible Overload Warnings fail to sound when platform is loaded beyond Rated Load, or when simulated by unplugging a Shear Pin Load Cell from the LSS Module. Controls remain functional at Platform and Ground Control positions.

The Host Control System is failing to regard the overload signal from the LSS Module, or the signal is shorted.

1. The Load Sensing System must be enabled within the Host Control System. Plug the JLG Analyzer into the Host Control System, enter the Access Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “CUTOUT PLT” should be displayed for European Community compliance (platform controls prevented during overload, ground controls remain operational). In country- or customer-specific circumstance, the selection “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).

2. (LE, MRT and RTS) - The signal between the LSS Module and the Host Control System is shorted. The Platform Module’s J1-20 is an input, and it connected to the J15 output on the LSS Module To examine the status of this signal, plug the JLG Analyzer into the Host Control System, enter the Access Level 1 password (33271), and examine the DIAGNOSTICS, SYSTEM, LOAD display. The display will indicate “OK” when the Platform Module’s input is energized (approximately 12V), and “OVERLOADED” when it is de-energized (0V). Refer to the Wiring Diagram for Load Sensing System for details

3. Observe the LSS Module’s assessment of overload using the JLG Analyzer plugged into the LSS Module’s connection. Proceed to the DIAGNOSTICS, OVERLOADED? display. The display should indicate “OVERLOADED? N” when the platform is empty, and “OVERLOADED? Y” when the platform is overloaded. If the assessment is improper, the difficulty may be a result of a General or Measurement Performance issue. Review the Possible Resolutions under those categories.

4. (LE, MRT and RTS) - If the LSS Module’s J1-5 Output does not appears to coincide with the DIAGNOSTICS, OVERLOADED? display, then the LSS Module is suspect. Substitute to determine cause of failure.

5-8 – JLG Lift – 3124288

Table 5-4. LSS Troubleshooting Chart - Host System Functionality

Difficulty Possible Resolution

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

Controls remain functional at the Ground Control position during an overload, or when simulated by unplugging a Shear Pin from the LSS Module. The Control at the Platform Control position are prevented.

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

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 Host Control System’s wiring harness using the wiring diagram to locate the difficulty.

2. Plug a JLG Analyzer into the LSS Module’s connection and ensure that the Host Control System is powered-up. When HELP:PRESS ENTER is displayed, press the ENTER key on the Analyzer. If “EVERYTHING OK” is displayed, it is probable that the Overload Signal from the LSS Module is not reaching the Host Control System. This signal is present on LSS Module’s J1-5 and is approximately 12V normally, and 0V during an overload. This signal eventually reaches the Main Terminal Box to provide the overload signal. Refer to the Wiring Diagram for wire color, number, and terminal information.

3. (LE, MRT and RTS) - If the Analyzer displayed “OVERLOADED” in the previous step, press the ENTER key again. If “NO CAL” is displayed, the Load Sensing System has not been properly calibrated. Refer to the Calibration portion of this manual.

4. If another fault is displayed, refer to the portion of this manual that describes Fault Messages and their causes.

5. The difficulty may be a result of a Measurement Performance issue. Review the Possible Resolutions under those categories.

The Host Control System is configured to prevent platform controls only in the event of overload (as required for EN280 compliance). Alternately, the Host Control System can be configured to prevent ground and platform controls for country- or customer-specific circumstances.

Plug the JLG Analyzer into the LSS Module’s connection and enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to “CUTOUT PLT” to prevent platform controls in the event of overload. Set this parameter to “CUTOUT ALL” to prevent platform and ground controls in the event of overload.

3124288 – JLG Lift – 5-9

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Figure 5-2. LSS Module Load Cell Connector

Pinout (J5, J6, J7, J8)

NOTE: Physical connector as viewed looking into the

cable end

Table 5-5. LSS Module System Interface Connector -

Power & Digital (J1 - Grey)

Pin Signal Description

1 VBAT Pos itive Power Supply from Host Control System

(12-24V)

2 GND Negative Power Supply from Host Control System

(0V)

3 GND-2 Connects to GND

4N/CUnused

5 DO1 Overload Indicator Output (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

Table 5-7. LSS Module Load Cell Connector Pinout (J5,

J6, J7, J8)

Pin Signal Description

1 + Signal Pos itive 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

Table 5-6. LSS Module System Interface Connector –

Communication (J1 - Black)

Pin Signal Description

1 APWR Pre-Regulated Supply for JLG Analyzer (Analyzer

Pin 1; approx. 12V)

2 TX 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 I nterface Low

10 TRP2 120 Ohm CANbus Terminator

11 RX RS-232 for JLG Analyzer (Analyzer Pin 2)

12 GND Ground for JLG Analyzer (Analyzer Pin 4)

5-10 – JLG Lift – 3124288

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Figure 5-3. 260MRT Wiring Diagram

3124288 – JLG Lift – 5-11

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Figure 5-4. M3369/M4069 & 3369LE/4069LE Wiring Diagram

5-12 – JLG Lift – 3124288

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Figure 5-5. 500RTS Wiring Diagram

3124288 – JLG Lift – 5-13

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Figure 5-6. ES Wiring Diagram

5-14 – JLG Lift – 3124288

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

Figure 5-7. RT Wiring Diagram

3124288 – JLG Lift – 5-15

SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT)

NOTES:

5-16 – JLG Lift – 3124288

SECTION 6. SERVICE - (RS)

SECTION 6 - SERVICE - (RS)

6.1 DESCRIPTION (RS)

The platform load sensing system is intended to prevent machine operation in the event that the platform is overloaded. Machine operation does not return until the platform overload is removed. If the platform load sensing system is equipped the machine will include 3 additional components, 2 pressure transducers and 1 angle sensor.

The pressure transducers, which are located at the barrel end of the lift cylinder, (See Figure 6-1. and Figure 6-2.) are intended to correlate hydraulic fluid pressure to the load placed in the platform. The angle sensor, located at the bottom of the arm stack to the rear of the 10RS, and underneath the platform at the rear of the machine on the 6RS, (See Figure 6-3.) is intended to correlate machine elevation with hydraulic fluid pressure as measured by the pressure transducers.

NOTE: JLG specifications require that this procedure be

performed every 500 machine hours or 6 months, whichever occurs first. Calibrating the platform load sensing system regularly is essential to safe machine operation. Continuing to operate a machine without calibrating at the recommended specifications could compromise machine stability resulting in a machine tip-over.

6.2 CALIBRATION (RS)

The load sensing system cannot be calibrated without first calibrating the machines Angle Sensor. The load sensing system will not measure load at or below the elevation switch trip point.

Angle Sensor Calibration Procedure (RS)

1. Ensure the batteries are fully charged and the hydraulic fluid level is acceptable.

2. Park the vehicle on a level surface. The platform should be fully stowed and level within +/- 0.5 degrees (both directions).

3. Remove the orange panel on the ground control key switch side of the machine.

4. Disconnect the MDI display and connect the JLG Analyzer.

5. Navigate to the ACCESS LEVEL menu on the Analyzer and enter the Access Level 1 code.

6. Execute a Angle Calibration via the JLG Analyzer. Proceed to the Analyzer's CALIBRATION top level menu and press ENTER. Navigate to the ANGLE submenu and press ENTER. Press ESC to abort a calibration or ENTER to calibrate. If successful the Analyzer will display COMPLETE!. If unsuccessful, a message will be displayed that will help lead to a

resolution (reference the Troubleshooting section of this manual). Press ESC to return to the top level menu.

Platform Load Sensing System Calibration Procedure (RS)

1. If the Angle Sensor has not been calibrated refer to the Angle Sensor Calibration Procedure first!

2. Ensure the batteries are fully charged and the hydraulic fluid level is acceptable.

3. Park the vehicle on a level surface. The platform should be fully stowed and level within +/- 0.5 degrees (both directions).

4. Ensure the temperature is greater than 32 degrees Fahrenheit.

5. Place weight corresponding to 110% of the machines rated load in the center of the platform. Secure the weight to the platform. See the chart below to determine the correct weight for calibration on each machine.

Table 6-1. Platform Calibration Weight - RS

MACHINE CALIBRATION WEIGHT

1932RS/6RS 550 lbs. (250 Kg)

3248RS/10RS 775 lbs. (352 Kg)

6. Remove the orange panel on the ground control key switch side of the machine.

7. Disconnect the MDI display and connect the JLG Analyzer.

8. Navigate to the ACCESS LEVEL menu on the Analyzer and enter the Access Level 1 code.

9. Execute a Load Calibration via the JLG Analyzer. Proceed to the Analyzer's CALIBRATION top level menu and press ENTER. Navigate to the LOAD submenu and press ENTER. Press ESC to abort a calibration or ENTER to calibrate. If successful the Analyzer will display COMPLETE!. If unsuccessful, a message will be displayed that will help lead to a resolution (reference the Troubleshooting section of this manual). Press ESC to return to the top level menu.

3124288 – JLG Lift – 6-1

SECTION 6 - SERVICE - (RS)

6.3 TESTING AND EVALUATION (RS)

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

1. Park the vehicle on a level surface. The platform should be fully stowed and level within +/- 0.5 degrees (both directions).

2. Ensure Pressure Transducers work appropriately. Proceed to the DIAGNOSTICS, LOAD submenu and ensure that PRES1 and PRES2 are within 10 PSI of 0 with the platform stowed. Engage lift up from the ground panel and ensure that the PRES1 and PRES2 readings begin to increase as the machine elevates.

3. Ensure the Angle Sensor works appropriately. Proceed to the DIAGNOSTICS, ANGLE submenu and ensure that ANGLE, ANGLE increases as the machine elevates and decreases as the machine descends.

4. Confirm Host Control System Warnings and Interlocks and Load Sensing System Performance with Calibrated Weights. Using the vehicle’s key switch select ground mode and power-up. Ensure that all controls are functional and the Load Sensing Systems Visual and Audible Warnings are not active. Engage lift up from the Ground Panel until the platform reaches maximum elevation, and then engage

lift down from the Ground Panel until the platform becomes stowed. Ensure that the Overload Visual and Audible alarm did not activate at either control position during this procedure. Ensure that the Load Sensing System activates with 120% rated load placed in the center of the platform. With the platform stowed engage lift up with 120% rated load placed in the center of the platform ensuring that the Load Sensing System activates within the ranges listed in the following table. Ensure that the DIAGNOSTICS, LOAD, OVERLOADED submenu reads YES. The Overload Visual Warning should flash at the selected control position and the Audible Warning should sound for 5 seconds On and 2 seconds Off. With the machine On all platform movement should be prevented. Cycle the Ground Panel Emergency Stop button. The Overload Visual and Audible Warning should continue. Pull the manual descent lever until the platform becomes stowed. The Overload Visual and Audible Warnings should cease and all normal control function should return.

Table 6-2. System Activation Height - RS

MACHINE SYSTEM ACTIVATION HEIGHT

1932RS/6RS 4.92 - 8.20 ft. (1.5 - 2.5m)

3248RS/10RS 8.20 - 11.48 ft. (2.5 - 3.5m)

6-2 – JLG Lift – 3124288

6.4 LSS TROUBLESHOOTING (RS)

The following tables are furnished to provide possible resolutions for common difficulties.

Table 6-3. LSS Troubleshooting - RS

PROBLEM POSSIBLE RESOLUTION

JLG Analyzer displays "MAX NOT IN RANGE" after the step "LIFT TO MAX" during Angle Calibration

JLG Analyzer displays "MAXANGLE TO HIGH" after the step "LIFT TO MAX" during Angle Calibration

JLG Analyzer displays "LOW NOT IN RANGE" after the step "LOWER TO STOWED" during Angle Calibration

JLG Analyzer displays "MINANGLE TOO LOW" after the step "LOWER TO STOWED" during Angle Calibration

JLG Analyzer displays "CAL FAIL!" at any time during the ANGLE calibration.

JLG Analyzer displays "INVALID RANGE" after the step "LOWER TO STOWED"

JLG Analyzer displays "NOT IN GND MODE" when attempting to perform a LOAD Calibration

JLG Analyzer displays "CAL ANGLE" when attempting to perform a LOAD Calibration.

The Angle Sensor’s upper limit is not acceptable. The Angle Sensor’s reading must fall within +/- 35 counts of 210 counts when the platform is at maximum elevation.

1. Check the Angle Sensor to ensure that it is installed properly and that no debris has become lodged around the Angle Sensor lever arm.

2. Ensure that the lever arm is installed properly and is not damaged.

The Angle Sensor's reading when the platform is at maximum elevation was greater than 245 counts. The Angle Sensor's reading when the platform is at maximum elevation must be a number less than or equal to 245 counts.

1. Check the Angle Sensor to ensure that it is installed properly and that no debris has become lodged around the Angle Sensor lever arm.

2. Ensure that the lever arm is installed properly and is not damaged.

The Angle Sensors lower limit is not acceptable. The Angle Sensor’s reading must fall within +/- 35 counts of 40 counts when the platform is stowed.

1. Check the Angle Sensor to ensure that it is installed properly and that no debris has become lodged around the Angle Sensor lever arm.

2. Ensure that the lever arm is installed properly and is not damaged.

The Angle Sensor's reading when the platform is stowed was less than 5 counts. The Angle Sensor's reading when the platform is stowed must be a number greater than or equal to 5 counts.

1. Check the Angle Sensor to ensure that it is installed properly and that no debris has become lodged around the Angle Sensor lever arm.

2. Ensure that the lever arm is installed properly and is not damaged.

The technician has pressed ESC on the Analyzer during the calibration routine or the Angle Sensor’s Range with the platform stowed to the platform at maximum elevation was not acceptable.

1. ESC was accidentally pressed during the Calibration procedure. The previously calibrated values will not be lost. Attempt ANGLE calibration again.

2. Check the Angle Sensor to ensure that it is installed properly and that no debris has become lodged around the Angle Sensor lever arm.

3. Ensure that the lever arm is installed properly and is not damaged.

The sensors range from stowed to maximum height was not acceptable.

1. Check to ensure that the Angle sensor is mounted properly.

2. Ensure that the angle sensors lever arm is still functioning properly and is not broken.

The machine is not in Ground Mode.

1. Re-attempt LOAD Calibration after setting the key switch to the Ground Control position.

The Angle Sensor has not been calibrated.

1. The Angle Sensor must be calibrated before a LOAD calibration can occur. Enter the CALIBRATIONS menu and perform an ANGLE calibration.

SECTION 6 - SERVICE - (RS)

3124288 – JLG Lift – 6-3

SECTION 6 - SERVICE - (RS)

Table 6-3. LSS Troubleshooting - RS (Continued)

PROBLEM POSSIBLE RESOLUTION

JLG Analyzer displays "MOTION STOPPED" after the LOAD calibration steps "LIFT TO MAX ELEV" or "LOWER TO STOWED".

JLG Analyzer displays "CAL FAIL!" when attempting to perform a LOAD Calibration.

The Visual and Audible Overload Warnings fail to sound when platform is loaded beyond rated load. Controls remain functional at Ground and Platform Control Positions.

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

Controls remain functional at the Ground Control position during an overload.

The Control at the Platform Control positions are prevented.

The platform stopped moving during LOAD calibration.

1. The technician let go of the lift up switch before the machine reached maximum elevation during "CAL LOAD: LIFT TO MAX ELEV" or the technician let go of the lift down switch before the machine became stowed after the "CAL LOAD: LOWER TO STOWED" step. Re-attempt LOAD calibration making sure not to disengage the lift up and lift down switch during these steps.

The technician has pressed ESC on the Analyzer during the calibration routine.

1. ESC was accidentally pressed during the Calibration procedure. The previously calibrated values will not be lost. Attempt LOAD calibration again.

The Load Sensing System is failing to detect that an overload condition exists or the Load Sensing system has not been enabled.

1. The Load Sensing System must be enabled within the Host Control System. Connect the JLG Analyzer and enter the Access Level 1 Password (33271). Navigate to MACHINE SETUP, LOAD submenu. The selection "CUTOUT PLT" should be displayed for European Community Compliance (platform controls prevented during overload, ground controls remain operational). In country- or customer-specific circumstances, the selection "CUTOUT ALL" is used (platform and ground controls prevented during an overload).

2. The Load Sensing System requires re-calibration. If the Load Sensing System fails to detect an Overload with 120% load placed in the platform perform an ANGLE calibration followed by a LOAD calibration as specified by the Calibration procedures listed in this document.

3. If a fault is displayed, refer to the portion of this manual that describes Fault Messages and their causes.

The Load Sensing System has not been calibrated or is experiencing a measurement performance difficulty.

1. The machine is assumed to be overloaded until the Load Sensing System has been calibrated. Navigate to the CALIBRATIONS menu and perform an ANGLE calibration followed by a LOAD calibration.

2. The Load Sensing System requires re-calibration. If the Load Sensing System falsely detects an Overload with less than rated load placed in the platform perform an ANGLE calibration followed by a LOAD calibration as specified by the Calibration procedures portion of this manual.

3. If a fault is displayed, refer to the portion of this manual that describes Fault Messages and their causes.

The Host Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control System can be configured to prevent ground and platform controls for country- or customer-specific circumstances.

1. Plug the JLG Analyzer in and enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to "CUTOUT PLT" to prevent platform controls in the event of overload. Set this parameter to "CUTOUT ALL" to prevent platform and ground controls in the event of overload.

6-4 – JLG Lift – 3124288

6.5 LSS COMPONENT REMOVAL/

INSTALLATION (RS)

Pressure Transducer Removal (RS)

(See Figure 6-1. and Figure 6-2.)

Use the following procedure to safely remove and repair the pressure transducers on the lift cylinder.

1. Ensure that the key switch is set to ground mode.

2. Engage lift up from the ground panel until the platform has elevated high enough to engage the lift cylinder safety prop.

3. Engage the platform safety prop.

4. Lower the platform on to the safety prop and continue to engage lift down for 1 second after the platform makes contact with the safety prop.

5. Disconnect power at the batteries.

6. Carefully disconnect the electrical connectors on each sensor.

7. Remove each pressure transducer.

Pressure Transducer Installation (RS)

1. Insert new pressure transducer and tighten.

2. Reconnect each pressure transducers electrical connector.

3. Reconnect power at the batteries.

4. Turn machine on and engage lift up from the ground panel so that the safety prop can be disengaged.

5. Lower the platform to the stowed position.

6. This completes pressure transducer repair.

SECTION 6 - SERVICE - (RS)

Figure 6-1. LSS Pressure Transducer Location -

1932RS/6RS

1. Ports On Barrel of Cylinder

2. Pressure Tran sdu cer s

3. Harness Connectors

Figure 6-2. LSS Pressure Transducer Location -

3248RS/10RS

1. Ports On Bottom of Cylinder

2. Pressure Transducers

3. Harness Connectors

3124288 – JLG Lift – 6-5

SECTION 6 - SERVICE - (RS)













10RS Angle Sensor Removal (RS)

(See Figure 6-1. and Figure 6-2.)

1. Ensure that the platform is stowed and the machine is on level ground.

2. Disconnect power at the batteries.

3. Locate the Angle Sensor at the back of the machine.

4. Disconnect the Angle Sensor’s electrical connection.

5. Remove the Angle Sensor.

10RS Angle Sensor Installation (RS)

1. Install the Angle Sensor with the mounting hardware.

2. Reconnect the Angle Sensor’s electrical connector.

3. Reconnect power at the batteries.

4. Recalibrate the machine’s Angle Sensor.

5. Recalibrate the machine’s Load Sensing System.

6RS Angle Sensor Removal (RS)

1. Ensure that the key switch is set to ground mode.

2. Engage lift up from the ground panel until the platform has elevated high enough to engage the lift cylinder safety prop.

3. Engage the platform safety prop.

4. Lower the platform on to the safety prop and continue to engage lift down for 1 second after the platform makes contact with the safety prop.

5. Disconnect power at the batteries.

6. Disconnect the Angle Sensor’s electrical connection.

7. Remove the Angle Sensor.

6RS Angle Sensor Installation (RS)

1. Install the Angle Sensor with the mounting hardware.

2. Reconnect the Angle Sensor’s electrical connector.

3. Reconnect power at the batteries.

4. Turn machine on and engage lift up from the ground panel so that the safety prop can be disengaged.

5. Lower the platform to the stowed position.

6. Recalibrate the machine’s Angle Sensor.

7. Recalibrate the machine’s Load Sensing System.

1932RS/6RS 3248RS/10RS

1. Platform Gate

2. LSS Scissor Arm Angle Sensor (rear plate shown cutaway)

3. Platform Entry Ladder

6-6 – JLG Lift – 3124288

Figure 6-3. LSS - Scissor Arm Angle Sensor - (RS)

1. Elevation Limit Switch Location

2. LSS Scissor Arm Angle Switch (scissor arms shown cutaway)

3. Platform Entry Ladder

LSS Connector Pin Assignments (RS)

SECTION 6 - SERVICE - (RS)

Table 6-4. Connections to Host Control System

(J1-Black) (RS)

PIN SIGNAL DESCRIPTION

1 PRES1 Pressure Transducer 1 Input (0-5V)

2 PRES2 Pressure Transducer 2 Input (0-5V)

16 PPRES Pressure Transducers Analog Reference (0-5V)

17 NPRES Pressure Transducers Negative Reference

Table 6-5. Connections to Host Control System

(J2-Blue) (RS)

PIN SIGNAL DESCRIPTION

5CANLCANbus Low

6CANHCANbus High

15 CANS CANbus Shield

22 NOVL Nagative for Overload Lamp (Low-Side Driver)

Table 6-6. Angle Sensor Connector Pinout (RS)

PIN SIGNAL DESCRIPTION

1 GND Angle Senso r Ground

2 PWR Angle Sensor Power (10 - 30V)

3 NC No Connect

4 NC No Connect

5 CANH Angle Sensor CANbus High

6 CANL Angl e Sensor CANbus Low

Table 6-7. Pressure Transducer Connector Pinout

(RS)

PIN SIGNAL DESCRIPTION

A PWR Pressure Transducer Power (+5V)

B GND Pressure Transducer Ground

C SIG Pressure Transducer Analog Output (0 - 5V)

3124288 – JLG Lift – 6-7

SECTION 6 - SERVICE - (RS)

ANGLE SENSOR

TRANSDUCER-1 TRANSDUCER-2

HOST CONTROL MODULE (ZAPI)

GROUND CONTROL

OVERLOAD LAMP

PLATFORM CONTROL

OVERLOAD LAMP

J1 - BLACK J2 - BLUE

PRES 1

PRES 2

PPRES

NPRES

CANL

CANH

CANS

NOVL

+5V

GND

PRES1

+5V

GND

PRES2

GND

PWR

CANL

CANH

– LB24

+ LB24

LB89 –

LB89 +

X12-19

X10-19

X28-19

X11-19

WHT 58 PRES1

WHT 59 PRES2

WHT 60 5V SEN

WHT 61 GND

BLK S34 (B–)

RED X25-7 (splice block)

YEL

SHIELD

S03

S04

GRN

YEL

SHIELD

GRN

WHT 42 OVERLOAD LAMP

WHT 42-1 OVLD LMP

WHT 42-2 OVLD LMP

GRN

(PLATFORM

CABLE)

X25-4

X48-7

YEL 3-15 IGN

YEL 3-16 IGN

6-8 – JLG Lift – 3124288

Figure 6-4. LSS - Electrical Component Schematic - (RS)

SECTION 7. PARTS

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

7-1 LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE) . . . . 7-2

7-2 LOAD SENSING SYSTEM INSTALLATION (500RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-3 LOAD SENSING SYSTEM INSTALLATION (1930ES/2030ES/2630ES/2646ES/3246ES) . . . . 7-8

7-4 LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/3248RS) . . . . . . . . . . . . . . . 7-12

7-5 LOAD SENSING SYSTEM INSTALLATION (34694RT/4394RT) . . . . . . . . . . . . . . . . . . . . . . . . 7-14

3124288 – JLG Lift – 7-1

FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069

LEFT FRONT

PLATFORM

SLIDE BLOCK

LEFT REAR PLATFORM

SLIDE BLOCK

RIGHT FRONT

PLATFORM

SLIDE BLOCK

RIGHT REAR

PLATFORM

SLIDE BLOCK

ANALYZER

GROUND

CONTROL

BOX

INDICATOR

LIGHT

LOAD

SENSE

POWER

SUPPLY

PLATFORM CONTROL BOX

INDICATOR

LIGHT

292929

20A

20B

34B

20B

34A

20B

33A

32A

32B

LE MACHINES

MRT MACHINES

LE MACHINES

159

33D

33C

33B

& 3369LE/4069LE)

7-2 – JLG Lift – 3124288

FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LOAD SENSING SYSTEM INSTALLATION Ref. 0272964 260MRT (Platform without D-Rings) Ref. F 0272965 260MRT (Platform with D-Rings) Ref. E 0272930 E/M3369/4069LE (Platform without D-Rings) Ref. I 0272931 E/M3369/4069LE (Platform with D-Rings) Ref. I

1 to 3 Not Used

4 Bolt Options: 3

0641405 Prior to S/N 0200120066 0641415 S/N 0200120066 to Present

5 to 6 Not Used

7 Bolt Options: 4

260MRT: 0641636 Bolt 3/8”-16NC x 4 1/2” (Prior to S/N 0200124148) 0701029 Bolt (Metric) M10 x 120mm (S/N 0200124148 to Pres-

ent)

E/M3369/4069LE: 3931648 Capscrew 3/8”-16NC x 3” (Prior to S/N 0200124146) 4032022 Capscrew (Metric) M10 x 90mm (S/N 0200124146 to

Present)

8 to 9 Not Used

10 Module, Load Sensing Options: 1

1600350 Prior to S/N 0200120066 1600387 S/N 0200120066 to Present

11 to 14 Not Used

15 3311405 Locknut 1/4”-20NC 3

16 to 17 Not Used

18 Locknut Options: 4

3311605 Locknut 3/8”-16NC (Prior to S/N 0200124146) 3291005 Locknut (Metric) M10 (S/N 0200124146 to Present)

19 Not Used

20 3422938 Pin, Load Management (Includes Harness) 4 E 20A Not Available Connector, Strain Relief 1 20B Not Available Plug, Male 6 Position 1

Not Available Socket, Female 6

21 to 28 Not Used

29 4751600 Flatwasher 3/8” 8

30 to 31 Not Used

32 4922904 Module to Analyzer Harness 1 B 32A 4460836 Plug, Male 12 Position 1

4460465 Socket, Female 4 4460466 Seal, Plug 8 0840055 Boot 1

32B 4460761 Connector, Female 4 Position 1

4460294 Pin, Male 4

33 Main Load Sensing Harness 1

4922915 260MRT (Prior to S/N 0200193881) A 4922903 E/M3369/4069LE (Prior to S/N 0200152398) B

3124288 – JLG Lift – 7-3

FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

33A 4460836 Plug, Male 12 Position 1

4460465 Socket, Female 4 4460466 Seal, Plug 8 0840055 Boot 1

33B 4460897 Connector, Female 2 Position 1

4460464 Pin, Male 2

33C 4460932 Connector, Female 4 Position 1

4460464 Pin, Male 4

33D 4460049 Connector, Strain Relief 1

34 1061020 Cable, Extension (E/M3369/4069LE Only) 2 B

34A Not Available Plug, Male 6 Position 1

Not Available Socket, Female 6

34B Not Available Connector, Female 6 Position 1

Not Available Pin, Male 6

SCISSOR ARMS INSTALLATIONS WITH LSS (LE ONLY) Ref.

1001110710 260MRT Ref. A

0275525 3369LE Ref. A 0275526 4069LE Ref. A

159 Load Sensing Harness Options:

4922915 260MRT (S/N 0200193881 to Present) A 4922903 E/M3369/4069LE (S/N 0200152398 to Present) B

7-4 – JLG Lift – 3124288

FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3124288 – JLG Lift – 7-5

FIGURE 7-2. LOAD SENSING SYSTEM INSTALLATION (500RTS)

7-6 – JLG Lift – 3124288

FIGURE 7-2. LOAD SENSING SYSTEM INSTALLATION (500RTS)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LOAD SENSING SYSTEM INSTALLATION (CE SPEC) Ref. 0272973 500RTS with Standard Deck Ref. E 0272975 500RTS with Mega Deck Ref. E

1 to 2 Not Used

3 Bolt Options: 3

0641406 Bolt 1/4”-20NC x 3/4” (Prior to S/N 0200120099) 0641416 Bolt 1/4”-20NC x 2” (S/N 0200120099 to Present)

4 to 5 Not Used

6 0641668 Bolt 3/8”-16NC x 8 1/2” 4

7 to 9 Not Used

10 Module, Load Sensing Options: 1

1600350 Prior to S/N 0200120099 1600387 S/N 0200120099 to Present

11 Not Used 12 3311405 Locknut 1/4”-20NC 3 13 3311605 Locknut 3/8”-16NC 4 14 Not Used

15 3422939 Pin, Load Management (Includes Harness) 4 D 15A Not Available Connector, Strain Relief 1 15B Not Available Plug, Male 6 Position 1

Not Available Socket, Female 6

16 to 19 Not Used

20 4240033 Tie-Strap 4

21 to 24 Not Used

25 4751600 Flatwasher 3/8” Wide 8

26 4922904 Module to Analyzer Harness 1 B 26A 4460836 Plug, Male 12 Position 1

4460465 Socket, Female 4 4460466 Seal, Plug 8 0840055 Boot 1

26B 4460761 Connector, Female 4 Position 1

4460294 Pin, Male 4

27 4922911 Main Load Sensing Harness 1 B 27A 4460933 Plug, Male 12 Position 1

4460465 Socket, Female 4 4460466 Seal, Plug 8 0840055 Boot 1

28 1061021 Cable, Extension 2 B 28A Not Available Plug, Male 6 Position 1

Not Available Socket, Female 6

28B Not Available Connector, Female 6 Position 1

Not Available Pin, Male 6

3124288 – JLG Lift – 7-7

FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/

LEFT FRONT

PLATFORM

SLIDE BLOCK

LEFT REAR

PLATFORM

SLIDE BLOCK

RIGHT FRONT

PLATFORM

SLIDE BLOCK

RIGHT REAR

PLATFORM

SLIDE BLOCK

ANALYZER

LOAD

SENSE

POWER

SUPPLY

614108B8B

11C

11B

11D

11A

131312

2646ES/3246ES)

7-8 – JLG Lift – 3124288

FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LOAD SENSING SYSTEM INSTALLATION (CE SPEC) Ref.

1930ES: Ref.

0272836 USA Built Machines Prior to S/N 0200150266 & Belgium

Built Machines Prior to S/N 1200007882

0275029 USA Built Machines S/N 0200150266 to Present & Bel-

gium Built Machines S/N 1200007882 to Present

2030ES/2630ES: Ref.

0272837 USA Built Machines Prior to S/N 0200152825 & Belgium

Built Machines Prior to S/N 1200008481

0274992 USA Built Machines S/N 0200152825 to Present & Bel-

gium Built Machines S/N 1200008481 to Present

2646ES/3246ES: Ref.

0272838 USA Built Machines Prior to S/N 0200151610 & Belgium

Built Machines Prior to S/N 1200008265

0274931 USA Built Machines S/N 0200151610 to Present & Bel-

gium Built Machines S/N 1200008265 to Present

1 to 3 Not Used

4 Bolt Options: 2

0701022 Bolt M10 x 70mm (1930ES) 0701024 Bolt M10 x 80mm (2030ES/2630ES/2646ES/3246ES)

5 Bolt Options: 2

0701026 Bolt M10 x 90mm (1930ES) 0701027 Bolt M10 x 100mm (2030ES/2630ES/2646ES/3246ES)

6 Module, Load Sensing Options: 1

USA Built Machines: 1600366 Prior to S/N 0200120069 1600387 S/N 0200120069 to Present

Belgium Built Machines: 1600366 Prior to S/N 1200001581 1600387 S/N 1200001581 to Present

7 3291005 Locknut M10 4

8 3422938 Pin, Load Management (Includes Harness) 4 E 8A Not Available Connector, Strain Relief 1 8B Not Available Plug, Male 6 Position 1

Not Available Socket, Female 6

9 Not Used 10 4191707 Screw M6 x 16mm 2 11 Module to Analyzer Harness Options: 1

USA Built Machines: 4922908 Prior to S/N 0200150266 D 4923228 S/N 0200150266 to Present B

Belgium Built Machines: 4922908 Prior to S/N 1200007882 D 4923228 S/N 1200007882 to Present B

11A 4460761 Connector, Female 4 Position 1

4460294 Pin, Male 4

Ref. M

Ref. D

Ref. N

Ref. C

Ref. M

Ref. B

3124288 – JLG Lift – 7-9

FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

11B 4460836 Plug, Male 12 Position 1

4460465 Socket, Female 8 4460466 Seal, Plug 4 0840055 Boot 1

11C 4460836 Plug, Male 12 Position 1

4460465 Socket, Female 3 4460466 Seal, Plug 10 0840055 Boot 1 3990110 Diode, Voltage Suppressor 1

11D 4460899 Connector, Female 6 Position 1

4460464 Pin, Male 5 12 1320318 Clamp 3 13 1380158 Clip 3 14 Plate, Cable Reel Options: 1

USA Built Machines:

3680055 Prior to S/N 0200113763

Use 4340931 S/N 0200113763 to S/N 0200121287 (was p/n

3200456)

4340931 S/N 0200121287 to Present

Belgium Built Machines:

3680055 Prior to S/N 1200002229

Use 4340931 S/N 1200002229 to S/N 1200001914 (was p/n

3200456)

4340931 S/N 1200001914 to Present 15 4240033 Tie-Strap (Not Shown) 1 16 Bolt Options: 3

USA Built Machines: 0700608 Bolt M6 x 16mm (Prior to S/N 0200120069) 0700617 Bolt M6 x 45mm (S/N 0200120069 to Present)

Belgium Built Machines: 0700608 Bolt M6 x 16mm (Prior to S/N 1200001581) 0700617 Bolt M6 x 45mm (S/N 1200001581 to Present)

17 3290606 Nut M6 3 18 4812000 Flatwasher 10mm 4 19 0100048 Grease, Dielectric (Not Shown) A/R

7-10 – JLG Lift – 3124288

FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3124288 – JLG Lift – 7-11

FIGURE 7-4. LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/

6RS/1932RS

6RS/1932RS (SHOWN)

10RS/3248RS (NOT SHOWN - TYPICAL)

10S/3248RS

45B

45A

3248RS)

7-12 – JLG Lift – 3124288

FIGURE 7-4. LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/3248RS)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LOAD SENSING SYSTEM INSTALLATION (CE SPEC) Ref. 1001147250 6RS/1932RS Ref. C 1001147251 10RS/3248RS Ref. C

1 to 5 Not Used

6 3290607 Locknut M6 1

7 to 34 Not Used

35 1001147340 Sensor, Pressure Transducer 2

See Note Harness (Note: Refer to Model Specific Parts Manual) 1

36 to 39 Not Used

40 3290405 Locknut M4 2

41 to 42 Not Used

43 4031512 Capscrew m4 x 40mm 2 44 Not Used 45 1001151800 Sensor, Angle 1

70004167 Arm 1 70004168 Pin, Dowel 1

See Note Harness (Note: Refer to Model Specific Parts Manual) 1

3124288 – JLG Lift – 7-13

FIGURE 7-5. LOAD SENSING SYSTEM INSTALLATION (3394RT/4394RT)

LEFT FRONT

PLATFORM

SLIDE BLOCK

LEFT REAR PLATFORM

SLIDE BLOCK

RIGHT FRONT

PLATFORM

SLIDE BLOCK

RIGHT REAR

PLATFORM

SLIDE BLOCK

MODULE

RIGHT FRONT

OF MACHINE

ANALYZER

PLATFORM

MODULE

CLADDER

ACCESSORY

16A

17A

14E

14D

14A

14C

14B

5A5A5A5B5B5B5B

17B

16B

17B

7-14 – JLG Lift – 3124288

FIGURE 7-5. LOAD SENSING SYSTEM INSTALLATION (3394RT/4394RT)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

LOAD SENSING SYSTEM INSTALLATION (CE SPEC) Ref.

0271683 3394RT/4394RT Ref. G

1 to 2 Not Used

3 Bolt Options: 4

0641660 Bolt 3/8”-16NC x 7 1/2” (Prior to S/N 0200124146) 0701037 Bolt (Metric) M10 x 200mm (S/N 0200124146 to Present)

4 Locknut Options: 4

3311605 Locknut 3/8”-16NC (Prior to S/N 0200124146) 3311605 Locknut (Metric) M10 (S/N 0200124146 to Present)

5 3422938 Pin, Load Management (Includes Harness) 4 E 5A Not Available Connector, Strain Relief 1 5B Not Available Plug, Male 6 Position 1

6 to 8 Not Used

9 0100011 Loctite #242 (Not Shown) A/R 10 Module, Load Sensing 1

1600350 Prior to S/N 0200119881

1600387 S/N 0200119881 to Present 11 0641405 Bolt 1/4”-20NC x 5/8” 3 12 0902837 Bracket, Module Mounting 1 13 4751400 Flatwasher 1/4” 3 14 4922882 Module to Analyzer Harness 1 C

14A 4460761 Connector, Female 4 Position 1

4460294 Pin, Male 4

14B 4460836 Plug, Male 12 Position 1

4460465 Socket, Female 8

4460466 Seal, Plug 4

0840055 Boot 1

14C 4460930 Plug, Male 8 Position 1

4460465 Socket, Female 5

4460466 Seal, Plug 3

0840058 Boot 1

14D 4460931 Connector, Female 8 Position 1

4460464 Pin, Male 5

4460466 Seal, Plug 3

0840058 Boot 1

14E 4460933 Plug, Male 12 Position 1

4460465 Socket, Female 2

4460466 Seal, Plug 10

0840055 Boot 1 15 3311405 Locknut 1/4”-20NC 3 16 1061020 Cable, Extension (1 Meter) 2 B

16A Not Available Plug, Male 6 Position 1

Not Available Socket, Female 6

16B Not Available Connector, Female 6 Position 1

Not Available Pin, Male 6

17 1061021 Cable, Extension (3 Meter) 2 B

17A Not Available Plug, Male 6 Position 1

Not Available Socket, Female 6

3124288 – JLG Lift – 7-15

FIGURE 7-5. LOAD SENSING SYSTEM INSTALLATION (3394RT/4394RT) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

17B Not Available Connector, Female 6 Position 1

Not Available Pin, Male 6

18 to 19 Not Used

20 4240033 Tie-Strap (Not Shown) A/R 21 Not Used 22 Bolt Options: 3

0641405 Bolt 1/4”-20NC x 5/8” (Prior to S/N 0200119881) 0641415 Bolt 1/4”-20NC x 1 7/8” (S/N 0200119881 to Present)

7-16 – JLG Lift – 3124288

McConnellsburg PA. 17233-9533

3124288

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

USA

(717) 485-5161

(717) 485-6417

JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia

+61 2 65 811111

+61 2 65 813058

JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755 Castellbisbal, Barcelona Spain

+34 93 772 4700

+34 93 771 1762

JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil

+55 19 3295 0407

+55 19 3295 1025

JLG Equipment Services Ltd. Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N. T. Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Sverige AB Enkopingsvagen 150 Box 704 SE - 176 27 Jarfalla Sweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

JLG Industries (UK) Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG Industries (Italia) s.r.l. Via Po. 22 20010 Pregnana Milanese - MI Italy

+39 029 359 5210

+39 029 359 5845

JLG France SAS Z.I. de Baulieu 47400 Fauillet France

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

Oshkosh-JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4, Jurong Industrial Estate Singapore, 639379

+65-6591 9030

+65-6591 9031

JLG LSS Boom User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

AGENERAL

CMAINTENANCE

B HYDRAULIC SYSTEM SAFETY

SECTION 1. ANALYZER OPERATION - ALL

1.1 INTRODUCTION & OPERATION

1.2 USING THE ANALYZER

1.3 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER

SECTION 2. OPERATION - (LE, MRT, RTS)

2.1 CONNECTING THE JLG CONTROL SYSTEM ANALYZER (LE, MRT & RTS)

2.2 HELP MENU & FAULT CODES (LE, MRT & RTS)

2.3 DIAGNOSTIC MENU (LE, MRT & RTS)

2.4 PERSONALITIES (LE, MRT & RTS)

2.5 MACHINE SETUP MENU (LE, MRT & RTS)

2.6 CALIBRATION MENU (LE, MRT & RTS)

2.7 JLG WORKSTATION IN THE SKY™ ACCESSORIES

SECTION 3. OPERATION - (ES, RT)

3.1 CONNECTING THE JLG CONTROL SYSTEM ANALYZER (ES & RT)

3.2 HELP MENU & FAULT CODES (ES & RT)

3.3 DIAGNOSTIC MENU (ES & RT)

3.4 PERSONALITIES (ES & RT)

3.5 MACHINE SETUP MENU (ES & RT)

3.6 CALIBRATION MENU (ES & RT)

SECTION 4. OPERATION - (RS)

4.1 CONNECTING THE JLG CONTROL SYSTEM ANALYZER (RS)

4.2 HELP MENU & FAULT CODES (RS)

4.3 DIAGNOSTIC MENU (RS)

4.4 PERSONALITIES MENU (RS)

4.5 CALIBRATION MENU (RS)

Angle Sensor Calibration (RS Only)

4.6 LOAD SENSING SYSTEM CALIBRATION (RS ONLY)

SECTION 5. SERVICE - (LE, MRT, RTS, ES, RT)

5.1 DESCRIPTION

5.2 CALIBRATION

Procedure

Te s t i n g & E v a l u a t i o n

5.3 TROUBLESHOOTING

SECTION 6. SERVICE - (RS)

6.1 DESCRIPTION (RS)

6.2 CALIBRATION (RS)

Angle Sensor Calibration Procedure (RS)

Platform Load Sensing System Calibration Procedure (RS)

6.3 TESTING AND EVALUATION (RS)

6.4 LSS TROUBLESHOOTING (RS)

Pressure Transducer Removal (RS)

Pressure Transducer Installation (RS)

10RS Angle Sensor Removal (RS)

10RS Angle Sensor Installation (RS)

6RS Angle Sensor Removal (RS)

6RS Angle Sensor Installation (RS)

LSS Connector Pin Assignments (RS)

SECTION 7. PARTS