Operation & Safety, Service &
Maintenance & Illustrated Parts
Manual Supplement
JLG
LOAD
SENSING
SYSTEM
Vertical Lift Products
P/N
3124289
July 29, 2013
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
INTRODUCTION
GENERAL
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.
MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
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.
3124289 – JLG Lift – A
INTRODUCTION
July 1, 2003 - Original issue of Manual
March 1, 2004 - Revised
May 17, 2005 - Revised
July 15, 2006 - Revised
March 31, 2011 - Revised
March 1, 2012 - Revised
August 11, 2012 - Revised
January 23, 2013 - Revised
July 29, 2013 - Revised
REVISION LOG
B – JLG Lift – 3124289
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
EFFECTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
SECTION 1 - OPERATION
1.1 INTRODUCTION & OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Overload Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overload Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
2.1 LOAD SENSING SYSTEM (LSS) DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Manually Propelled Vertical Lift - Overload Detection (Manually Propelled Lifts). . . . . . . . . . 2-1
Drivable Vertical Lift - Overload Detection (Drivable Vertical Lifts) . . . . . . . . . . . . . . . . . . . . .2-1
2.2 LSS - SETUP AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Procedure Overview (All Vertical Lifts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Adjustment Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
LSS Operation Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.3 COMPONENT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
LSS Panel Component Installation - (Manually Propelled Lifts Only). . . . . . . . . . . . . . . . . . .2-5
LSS Indicators (Drivable Vertical Lifts Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
LSS Platform Mount Attach Arms to Mast Header Installation (All Lifts). . . . . . . . . . . . . . . . . 2-6
LSS Limit Switch Installation (All Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
LSS Platform Mount, Coil Spring to Mast Crossmember Installation (All Lifts) . . . . . . . . . . . 2-6
2.4 LSS TIMING MODULE - (MANUALLY PROPELLED LIFTS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 GROUND CONTROL MODULE (DRIVABLE VERTICAL LIFTS ONLY) . . . . . . . . . . . . . . . . . . . . . . 2-8
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.6 PLATFORM CONTROL CONSOLE (DRIVABLE VERTICAL LIFTS ONLY) . . . . . . . . . . . . . . . . . . .2-8
2.7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
SECTION 3 - ILLUSTRATED PARTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3124289 – JLG Lift – i
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. L.S.S. Indicator Panel Location - (Manually Propelled Vertical Lifts) . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2. Load Sensing System - Indicators (Drivable Vertical Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
2-1. Load Sensing System - Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-2. Load Sensing System - Indicators (Drivable Vertical Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-3. Platform Console LED Indicators (Drivable Vertical Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-4. LSS Component Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-5. LSS Wiring Diagram - (For Manually Propelled Vertical Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-6. LSS Wiring Diagram - (For Drivable Vertical Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
3-1. Platform Support & Load Sensing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
2-1 Test Weight Requirement Per Machine Model. (Percent of Maximum Platform Capacity) . . . . . .2-3
2-2 LSS Timing Module (J1 - Black Connector) Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-3 Ground Control Module Programming - Drivable Lifts ONLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-4 Troubleshooting - Machine Indicates (Possible False) Platform Overload Condition -
(Manually Propelled Vertical Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-5 Troubleshooting - Machine Indicates (Possible False) Platform Overload Condition -
(Drivable Vertical Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
ii – JLG Lift – 3124289
SECTION 1. OPERATION
–+
NOTE: This manual is intended as a supplement to the indi-
vidual machine’s Operators and Safety Manual, Service and Maintenance Manual and Illustrated Parts
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 Load Sensing System (LSS) for Vertical Mast
Products is designed to detect when actual platform load
exceeds the machine’s Maximum Rated Load Capacity.
Overload Indication
When the Maximum Rated Load Capacity is exceeded the
following will occur:
SECTION 1 - OPERATION
NOTE: There is a three (3) second delay between detection
and overload indication.
MANUALLY PROPELLED LIFTS (See Figure 1-1.)
1. The LSS Warning Alarm and Lamp will activate 1
second ON, and 2 seconds OFF.
2. The platform lift up/down function will be disabled to
prevent movement of the overloaded platform.
DRIVABLE LIFTS (See Figure 1-2.)
1. The LSS Warning Alarm and Lamp will activate 5
seconds ON, and 2 seconds OFF. Also a 9 LED
code will flash on the platform control console (see
below), and the Ground Control Module LCD screen
will indicate a platform overload condition.
2. The platform lift up/down and driving functions will
be disabled to prevent movement of the overloaded
platform.
NOTE: Ground control functions may be disabled depen-
dent on Ground Control Module programming.
Figure 1-1. L.S.S. Indicator Panel Location -
(Manually Propelled Vertical Lifts)
1. Platform Control Panel 3. LSS Warning Alarm
2. L.S.S. Indicator Panel 4. LSS Warning Lamp
Platform Console LED Indicators
(Drivable Vertical Lifts)
1. The platform console LED bar will flash 9 (Nine) LEDs
to indicate a Platform Overload condition.
3124289 – JLG Lift – 1-1
Figure 1-2. Load Sensing System - Indicators
(Drivable Vertical Lifts)
1. Ground Control Module 3. LSS Warning Lamp
2. LSS Warning Decal 4. LSS Warning Alarm
SECTION 1 - OPERATION
Overload Recovery
Further movement of the platform is permitted by removing excess platform load until the LSS resets. This may
require removing load until a load less than rated capacity
is achieved.
NOTE: There is a 5 second delay between overload reset
and machine function activation.
THE LOAD SENSING SYSTEM WILL REQUIRE ADJUSTMENT
WHEN ONE OR MORE OF THE FOLLOWING CONDITIONS
OCCUR:
• Load Sensing System initial installation
• LSS component is disassembled or replaced
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION
VERIFICATION NOT TO EXCEED 6 MONTHS FROM PREVIOUS
VERIFICATION.
1-2 – JLG Lift – 3124289
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
32491011781
6
5
SECTION 2. SERVICE PROCEDURES - LOAD SENSING SYSTEM
2.1 LOAD SENSING SYSTEM (LSS) DESCRIPTION
The LSS system for Vertical Mast model machines consists of a floating platform mount weldment (rails)
attached to the sides of the mast header section, transferring the platform load to a load bearing crossmember. The
platform mount load bearing crossmember is supported
by coil springs mounted between the platform crossmember and a crossmember attached to the mast header section. Also attached to the platform mount weldment (rails)
is an adjustable actuator. The actuator, when adjusted
properly, trips the LSS limit switch mounted on the mast
crossmember when the platform is overloaded.
While the mechanical portion of the LSS system operates
the same for both the manually propelled and drivable
vertical lifts, the limit switch circuit (electrical) is monitored
differently as described following.
Manually Propelled Vertical Lift - Overload Detection
(See Figure 2-1.)
The limit switch circuit on the manually propelled lifts is
monitored by an LSS Timing Module which disables the
platform lift up/lift down function, sounds an audible warning alarm and activates a flashing warning lamp when a
platform overload condition is detected. The LSS Timing
Module is mounted behind the LSS Indicator Panel
located behind the platform railing.
Drivable Vertical Lift - Overload Detection
(See Figure 2-1., Figure 2-2. and Figure 2-3.)
The limit switch circuit on the drivable lift is monitored by
the Ground Control Module (GCM) which controls all
machine functions and is mounted inside the machine’s
rear covers. Like the LSS Timing Module on the manually
propelled lifts, on overload detection the GCM on the drivable lift disables the platform lift up/lift down function, in
addition the drive function is also disabled. Indicators of
an overload condition are; an audible warning alarm;
flashing warning lamp; 9 LEDs flash on the platform control console and GCM LCD screen will flash "Platform
Overload". On the drivable lift, the audible warning alarm
and flashing warning lamp are located on the machine’s
left rear cover. (See Figure 2-2.)
On initial LSS installation or GCM replacement, the GCM
must be programmed to detect the LSS system in order to
function properly. See Section 2.5, "Ground Control Module" in this manual for instructions on GCM - LSS detection programming.
Figure 2-1. Load Sensing System - Components.
1. LSS Timing Module (a) 7. Crossmember Stops
2. LSS Indicator Panel (a) 8. LSS Overload Actuator
3. LSS Warning Lamp (b) 9. LSS Limit Switch
4. LSS Warning Alarm (b) 10. Mast Header
5. Platform Mount (c) 11. LSS Arm Linkage
6. Coil Spring Assemblies
Note: (a) Manually propelled lifts only.
(b) Relocated on drivable lifts (See Figure 2-2.)
(c) Shown cut-away for illustrative purposes only.
3124289 – JLG Lift – 2-1
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
–+
Figure 2-2. Load Sensing System - Indicators
(Drivable Vertical Lifts)
1. Ground Control Module 3. LSS Warning Lamp
2. LSS Warning Decal 4. LSS Warning Alarm
2.2 LSS - SETUP AND ADJUSTMENT
Procedure Overview (All Vertical Lifts)
The mechanical portion of the LSS system requires three
(3) adjustments to operate properly.
• Platform Crossmember/Coil Spring Pre-load Height
Adjustment; sets the coil spring pre-load between the
platform and mast crossmember with no load in the
platform.
• Mast Header Crossmember Positive Stop Adjust-
ment; sets the maximum amount of downward travel of
the platform, if the platform is overloaded.
• LSS Overload Actuator Adjustment; sets the actuator
to trip the LSS limit switch, signaling an overload situation, when the platform is overloaded. There is a three
(3) second delay between switch opening and warning
activation.
THESE SETUP PROCEDURES WILL REQUIRE ACCURATELY
MEASURED WEIGHT UP TO AND OF A PERCENTAGE OVER THE
PLATFORM’S MAXIMUM CAPACITY. SEE TABLE 2-1 IN THE FOLLOWING SUB-SECTION.
Figure 2-3. Platform Console LED Indicators
(Drivable Vertical Lifts)
1. The platform console LED bar will flash 9 (Nine) LEDs
to indicate a Platform Overload condition.
Figure 2-4. LSS Component Adjustments
1. Coil Spring Pre-Load Height Adjustment
2. Crossmember Positive Stop Adjustment
3. Overload Actuator Adjustment
Notes: Shown with manual storage box removed and
with little or no load in the platform.
2-2 – JLG Lift – 3124289
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
Adjustment Preparation
Before performing the LSS adjustments:
• Move machine to a smooth, firm, level surface.
• Remove the platform manual storage box from main
mast header. The storage box fasteners are located
inside the manual storage box.
• Have applicable test weight to maximum platform
weight capacity, plus percentage of overload amount
available with equipment capable of hoisting the weight
into the platform.
• Set-up machine for normal operation.
Table 2-1. Test Weight Requirement Per Machine Model.
(Percent of Maximum Platform Capacity)
OVERLOAD
MODEL
ADJUSTMENT
TEST WEIGHT
All Vertical Lifts 110% 120%
Example:
110% Overload Test Weight = Max. Platform Capacity + 10%
120% Positive Stop Test Weight = Max. Platform Capacity + 20%
Capacity 110% 120%
300 lb.
(136kg)
350 lb.
(159kg)
500 lb.
(227kg)
330 lb.
(150kg)
385 lb.
(175kg)
550 lb.
(250kg)
WHEN PERFORMING THE FOLLOWING ADJUSTMENTS - DO NOT
ADD TO THE WEIGHT IN THE PLATFORM BY ALLOWING ANY
PART OF YOUR BODY TO REST ON THE PLATFORM.
POSITIVE STOP
TEST WEIGHT
360 lb.
(163kg)
420 lb.
(191kg)
600 lb.
(272kg)
Adjustment Procedures
Coil Spring Pre-Load Adjustment Procedure
(As viewed from rear with mast hidden)
1. Perform the spring pre-load adjustment with NO
LOAD IN THE PLATFORM.
2. Adjust the coil spring height (item 1) between the
mast crossmember (item 2) and the platform crossmember (item 3) to two (2) inches (51mm) by loosening or tightening the locknut on the bottom of the
center bolt (item 4) (see note below).
3. Adjust outside spring bolts (items 5) until the locknuts
on the bottom of the bolts are flush with the end of
each bolt. The outside bolts will be loose.
NOTE: Machines with capacities up to 300 lb. (136kg)
only require two coils springs installed on the
outside bolt positions. Machines with capacities
over 300 lb. (136kg) require coil springs installed
in all three bolt positions.
3124289 – JLG Lift – 2-3
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
WHEN PERFORMING THE FOLLOWING ADJUSTMENTS - DO NOT
ADD TO THE WEIGHT IN THE PLATFORM BY ALLOWING ANY
PART OF YOUR BODY TO REST ON THE PLATFORM.
Limit Switch Overload Actuator Adjustment
1. Perform the limit switch overload actuator adjustment
with 110% OF MAXIMUM CAPACITY load in the platform.
2. Setup and power machine on.
Crossmember Positive Stop Adjustment
1. Perform the crossmember positive stop adjustment
with 120% OF MAXIMUM CAPACITY load in the platform.
2. Adjust the height between the top of the positive stop
bolts (item 3) and the platform crossmember (item 1)
to 1/16 - 1/8 inch (2 to 3mm) (item 2) by loosening
the nuts (item 4) at the bottom of the bolts (item 1).
Adjust both stop bolts until the proper height is
achieved.
3. Tighten both nuts (item 4) when proper adjustment is
achieved.
3. With weight in platform, loosen the actuator lock nut
(item 1) and turn the actuator (item 2) and align with
the end of plunger on the switch (item 3).
4. Remove the limit switch cover (item 4) and use a volt/
ohm meter to watch for switch open circuit. Adjust the
actuator down until the switch contact opens. (See
Notes (a) and (b).
5. Once circuit is open, re-tighten the actuator lock nut
and replace the cover on the limit switch when complete.
NOTE: (a) There is a three (3) second delay pro-
grammed into the LSS Timing Module (Manually
Propelled Lifts) and Ground Control Module
(Driveable Vertical Lifts) between switch opening
and module activation of the LSS warning indicators.
NOTE: (b) There is a 5 second RESET delay once the
limit switch circuit is closed and before the module resumes normal machine operation.
LSS Operation Function Check
After performing the adjustments outlined previously
check the following:
• Machine operates properly when loaded to 100% rated
platform capacity.
• Machine cuts out applicable functions and indicates an
overload condition when loaded to 110% rated platform
capacity.
2-4 – JLG Lift – 3124289
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
1
2
3
2.3 COMPONENT REMOVAL
General
Before disconnecting any electrical component always
turn off the machine power supply.
Refer to wiring schematic in the Troubleshooting section
for wiring connection information.
Platform removal will depend on machine model, consult
the machine’s Service/Maintenance Manual.
LSS Panel Component Installation - (Manually Propelled Lifts Only)
LSS Panel Installation
1. LSS Panel 3. Drop panel down and lift out
2. Panel Fasteners
Note: Wiring harness connectors to module, alarm and
lamp may need to be disconnected when removing
panel.
LSS Warning Alarm Installation
1. Alarm Body 2. Alarm Attach Nut
LSS Warning Lamp Installation
1. Lamp Attach Nut and Washer
2. Lamp Assembly
Note: Shown with alarm removed for illustrative purposes
only.
1. LSS Indicator Panel 3. LSS Timing Module
2. Module Fasteners
LSS Timing Module Installation
3124289 – JLG Lift – 2-5
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
LSS Indicators (Drivable Vertical Lifts Only)
LSS Indicator Installation (Drivable Lifts Only)
1. Open/unbolt Left Rear Cover 3. LSS Warning Alarm
2. LSS Warning Lamp
LSS Platform Mount Attach Arms to Mast Header Installation (All Lifts)
LSS Limit Switch Installation (All Lifts)
LSS Limit Switch Installation
1. Switch Mounting Nut (a) 3. Switch Fasteners
2. Limit Switch
Note: (a) Located behind mast crossmember.
LSS Platform Mount, Coil Spring to Mast Crossmember Installation (All Lifts)
View From Rear Of Crossmembers
(View From Rear - Mast Header Hidden)
Platform Mount to Mast Header Attach Arm Installation
(Top Side Arm Shown - Installation Same Both Sides)
1. Shoulder Bolt (2.75 in.) 5. Bronze Washer (.125 in.)
2. Shoulder Bolt (1.5 in.) 6. Hex Nuts (a)
3. Bronze Washer
4. Attach Arm Assy. 8. Platform Mount Assy.
Note: (a) Apply Loctite #271 to threads on final assembly
and torque to 45 ft. lb. (61 N, m).
(.0625 in.) 7. Mast Header
1. Platform Mount Crossmember 4. Coil Springs (a)
2. Spring Preload Adjust Bolts 5. Lock Nuts
3. Flat Washers 6. Mast Header Crossmember
NOTE: (a) Machines with capacities up to 300 lb.
(136kg) only require two coils springs installed
on the outside bolt positions. Machines with
capacities over 300 lb. (136kg) require coil
springs installed in all three bolt positions.
2-6 – JLG Lift – 3124289
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
12
3
4
Load Sensing System
Timing Module
P/N 1600357
S/N_________________________________
HW Rev.________ SW Rev.________
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
IGNITION
GROUND
Over loa d Limi t S wit ch i nput
Spare I nput 1
Spare I nput 2
Spare I nput 3
Over loa d Sta tus Ou tpu t
Visual Warning Output
Audible Warning Output
Spare Out put 3
Spare Out put 4
Spare Out put 5
+5 An alo g Re fer en ce
Spare Ana log 0
Analog Ground
+5 An alo g Re fer en ce
Spare Ana log 1
Analog Ground
Spare Ana log 2
Spare Ana log 3
CANBus CANH
CANBus CANL
Analyzer Pin #3
Analyzer Pin #2
PIN FUNCTION
PIN FUNCTION
J1 - BLACK J2 - GREY
1705760A
1
23
45
2.4 LSS TIMING MODULE (MANUALLY PROPELLED LIFTS ONLY)
The LSS Timing Module is fastened to the back of the LSS
Indicator Panel at the back of the platform on the mast
header. (See Section 2.3, Component Removal for instruc-
tions on removing the module).
LSS Module Location
1. Timing Module 3. J2 Grey Connector
2. J1 Black Connector 4. LSS Indicator Panel
LSS Timing Module Identification Decal
with Connector Pin Assignments
1. Module Serial Number
2. Hardware Revision Level
3. Software Revision Level
4. J1 Black - Pin Assignments (used)
5. J2 Grey - Pin Assignments (unused)
Table 2-2. LSS Timing Module
(J1 - Black Connector)
Pin Assignments
1. Timing Module 3. J2 Grey Connector (unused)
2. Identification Decal 4. J1 Black Connector (used)
LSS Timing Module
3124289 – JLG Lift – 2-7
Pin Signal Description
112V +Ignition
2Neg. (—)Ground
312V +Overload Limit Switch Input
4–Spare Input 1
5–Spare Input 2
6–Spare Input 3
712V +Overload Status Output
812V +Visual Warning Output
912V +Audible Warning Output
10 – Spare Input 4
11 – Spare Input 5
12 – Spare Input 6
Note: Also refer to wiring diagram Figure 2-5.
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
00000.0
1
2
–+
2.5 GROUND CONTROL MODULE (DRIVABLE VERTICAL LIFTS ONLY)
The following instructions are supplemental to the DVL/
DVSP Operators and Service manuals and show additional features on the ground control module for machines
equipped with the Load Sensing System.
Programming
The Ground Control Module must be programmed to
detect the Load Sensing System before the LSS will function properly.
1. Enter the Service Programming Mode (Level 2 -
Password) at the Ground Control Module (Refer to
the machine’s Service Manual for instructions).
2. Enter the Program menu and scroll through the item
list to find and set the LSS programming item range
as shown following:
Table 2-3. Ground Control Module Programming -
Drivable Lifts ONLY.
PROGRAMMABLE
ITEM
Enable Detection of
LSS
FACTORY
PRESET
2 0 - Detection Disabled
SETTING RANGE
1 - Enabled - Warning Disables
Platform Functions Only
2 - Enabled - Warning Disables
Platform and Ground
C o nt r ol F un c ti o ns
2.6 PLATFORM CONTROL CONSOLE (DRIVABLE VERTICAL LIFTS ONLY)
Platform Console LED Indicators
1. The platform console LED bar will flash 9 (Nine) LEDs
to indicate a Platform Overload condition.
LCD Display
When an overload warning is detected the following alternating screens are displayed on the Ground Control Module LCD screen:
LCD Display Symbols
1. Drive and Lift Up/Down Functions - Disable Indicators
2. Description of Warning - Platform Overloaded
Note: When the Overload condition is indicated the LCD screen will
alternate between the text and symbol display modes.
2-8 – JLG Lift – 3124289
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
2.7 TROUBLESHOOTING
The following tables are furnished to provide possible resolutions for common Load Sensing System difficulties.
The wiring connectors and pins referenced in these troubleshooting tables can be located on the electrical wiring
diagrams on the pages following these tables.
Table 2-4. Troubleshooting - Machine Indicates (Possible False) Platform Overload Condition -
(Manually Propelled Vertical Lifts)
Check For These Obvious Conditions First:
• Is the LSS platform mounting system secure and undamaged and all mounting arm joints working smoothly.
• Damaged or loose connectors or wires to LSS components.
STEP ACTION SPEC YES NO
1. Is platform load at or below the maximum rated platform capacity? See Capacity
Go to Step 2 Reduce Platform
Decal on Machine
2. Perform adjustment procedures (Section 2.2, LSS - Setup And
– Go to Step 3 Done
Adjustment). Reload platform to rated capacity, is system still indicating an overload condition?
3. Set up and power machine on. Check voltage at Timing Module - J1
connector - Pin 3. Is voltage up to spec?
4. Check continuity between Timing Module J1 - Pin 3 and Pin 22 on
12V Replace Timing
Module
Go to Step 5 Repair or Replace
the Limit Switch. Is there continuity?
5. At the Limit Switch check voltage on Pin 21. Is voltage up to spec? 12V Replace Limit
Switch
6. At the Limit Switch, check Pin 21 connector for loose or damaged
condition. Is connector loose or damaged?
Table 2-5. Troubleshooting - Machine Indicates (Possible False) Platform Overload Condition -
(Drivable Vertical Lifts)
Check For These Obvious Conditions First:
• Is the LSS platform mounting system secure and undamaged and all mounting arm joints working smoothly.
• Damaged or loose connectors or wires to LSS components.
– Repair or Replace
Connector
Load
Go to Step 4
Wiring
Go to Step 6
Replace Limit
Switch
STEP ACTION SPEC YES NO
1. Is platform load at or below the maximum rated platform capacity? See Capacity
Decal on Machine
Go to Step 2 Reduce Platform
Load
3124289 – JLG Lift – 2-9
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
Table 2-5. Troubleshooting - Machine Indicates (Possible False) Platform Overload Condition -
(Drivable Vertical Lifts)
STEP ACTION SPEC YES NO
2. Perform adjustment procedures (Section 2.2, LSS - Setup And
Adjustment). Reload platform to rated capacity, is system still indicating an overload condition?
3. Check continuity between Ground Control Module - P2 connector Pins 4 and 13. Is there continuity?
4. Check continuity from Limit Switch Terminal 22 to the Ground Control Module - P2 Connector - Pin 4. Is there continuity?
5. Check continuity from Limit Switch Terminal 21 to the Ground Control Module - P2 connector - Pin 13. Is there continuity?
– Go to Step 3 Done
Replace Ground
G o t o St e p 4
Control Module
Go to Step 5 Repair or Replace
Wiring
Readjust or
Replace Limit
Repair or Replace
Wiring
Switch
2-10 – JLG Lift – 3124289
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
Figure 2-5. LSS Wiring Diagram - (For Manually Propelled Vertical Lifts).
3124289 – JLG Lift – 2-11
SECTION 2 - SERVICE PROCEDURES - LOAD SENSING SYSTEM
AUX #2
1
2
3
Figure 2-6. LSS Wiring Diagram - (For Drivable Vertical Lifts).
1. Wires from Platform Junction Box - Auxiliary Connector to LSS Limit Switch 3. LSS Warning Alarm
2. LSS Warning Lamp
2-12 – JLG Lift – 3124289
SECTION 3. PARTS
TABLE OF CONTENTS
FIgure Description Page
3-1 LOAD SENSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3124289 – JLG Lift – 3-1
31
41
41
4040272829
2
23
15
5
15
26
15
6
10
11
3
4
16
21
21
1A1A20
20
14
14
17
1
103
304
302
303
10915104
209
101
202
105
210
106
211
18
18
30115102
108
107
25
13
2222221919
8
8
131212
12
9
777
24
B
C
A
B
C
A
Figure 3-1. PLATFORM SUPPORT & LOAD SENSING INSTALLATION
3-2 – JLG Lift – 3124289
.
FIGURE 3-1 PLATFORM SUPPORT & LOAD SENSING INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
LOAD SENSING SYSTEM INSTALLATION (CE SPEC) Ref.
0273264 20AM/25AM Models Ref. C
0273265 30AM/36AM/41AM Models Ref. C
0273264 AMI Models Ref. C
0273266 DVL/DVSP/MVL/MSP Models with Bolt-on Platforms Ref. D
0273267 DVL/DVSP/MVL/MSP Models with Quick Change
Ref. D
Platforms
0273047 MP Models Ref. D
1 0273144 Arm Assembly 4
0440268 Bushing ( 2 Per Arm) 8
2 0273162 Load Sensor Controller Assembly (See Items 101-109)
1
(Note: Machine must be recalibrated when replaced)
Note: Used on all Machines except DVL/DVSP/MVL/MSP
Models.
3 0630570 Bolt, Special 1
4 Bolt 1/4-20NC x 2” Options: A/R
0641416 AM/AMI Models 4
Not Required DVL/DVSP/MVL/MSP Models with Bolt-on Platforms 0
0641416 DVL/DVSP/MVL/MSP Models with Quick Change Plat-
4
forms
Not Required MP Models 0
5 Bolt 1/4-20NC x 2 1/4” Options: A/R
0641418 AM/AMI Models 4
Not Required DVL/DVSP/MVL/MSP Models with Bolt-on Platforms 0
0641418 DVL/DVSP/MVL/MSP Models with Quick Change Plat-
4
forms
Not Required MP Models 0
6 0641620 Bolt 3/8”-16NC x 2 1/2” 2
7 0641628 Bolt 3/8”-16NC x 3 1/2” 3
8 0791610 Screw 3/8”-16NC x 1 1/4” 4
9 3300475 Nut 1
10 3311401 Nut 1/4”-20NC 1
11 3311601 Nut 3/8”-16NC 2
12 3311605 Locknut 3/8”-16NC 3
13 3311608 Nut, Flanged 3/8”-16NC 4
14 3311801 Nut 1/2”-13NC 8
15 3820032 Rivet 10
16 3900346 Bolt, Shoulder 3/8” x 3/4” 4
17 3900347 Bolt, Shoulder 3/8” x 2” 4
18 3911024 Screw #10-24NC x 1 1/2” 2
19 4160205 Spring Options: A/R
20AM/25AM Models 2
30AM/36AM/41AM Models 3
AMI Models 2
DVL/DVSP/MVL/MSP Models 3
MP Models 3
20 4740529 Thrustwasher, Bronze 8
21 4740530 Thrustwasher, Bronze 8
22 4751600 Flatwasher 3/8” Wide 6
3124289 – JLG Lift – 3-3
FIGURE 3-1 PLATFORM SUPPORT & LOAD SENSING INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
23 4846859 Load Sensor Weldment 1
24 4846877 Support, Spring & Switch 1
25 Load Sensing Harness Assembly Options: 1
4922923 AM/AMI/MP Models (See Items 301-304 for Breakdown)
4922924 DVL/DVSP/MVL/MSP Models (See Items 401-404 for
Breakdown)
26 4061060 Shield 2
27 0721006 Screw, Machine #10-24NC x 3/4” 1
28 3311001 Nut #10-24NC 1
29 4771000 Starwasher #10 2
30 0100019 Loctite #271 (Not Shown) A/R
31 3520072 Cap-Plug 2
32 to 39 Not Used
40 Bolt 3/8”-16NC x 3 1/4” Options: A/R
Not Required AM/AMI Models 0
0641626 DVL/DVSP/MVL/MSP Models with Bolt-on Platforms 6
Not Required DVL/DVSP/MVL/MSP Models with Quick Change Plat-
forms
0641626 MP Models 6
41 4711600 Flatwasher 3/8” Narrow (MP Models Only) 3
0
0273162 LOAD SENSOR CONTROLLER ASSEMBLY
Note: Used on all Machines except DVL/DVSP/MVL/MSP
Models.
101 0140011 Alarm, Warning 1
102 0791408 Screw 1/4”-20NC x 1” 2
103 1600357 Module, Control 1
104 1705756 Decal - Warning 1
105 2920026 Lamp, Indicator 1
106 2920029 Bulb, Light 1
107 3311408 Nut, Flanged 1/4”-20NC 2
108 3574518 Plate, Mounting 1
109 4460908 Connector, Female 12 Position 1
LOAD SENSING SYSTEM INSTALLATION (CE SPEC)
Note: Components Located on Hood.
0273266 DVL/DVSP/MVL/MSP Models with Bolt-on Platforms Ref. D
0273267 DVL/DVSP/MVL/MSP Models with Quick Change Plat-
forms
201 Not Used
202 0140011 Alarm, Warning 1
203 to 208 Not Used
209 1705756 Decal - Warning 1
210 2920026 Lamp, Indicator 1
211 2920029 Bulb, Light 1
Ref. B
Ref.
Ref. D
3-4 – JLG Lift – 3124289
FIGURE 3-1 PLATFORM SUPPORT & LOAD SENSING INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
4922923 LOAD SENSING HARNESS ASSEMBLY
(AM/AMI/MP MODELS)
301 4360546 Switch, Limit 1
302 4460320 Plug, Male - 2 Position 1
4460226 Socket, Female 2
4460424 Connector, Female - 2 Position 1
4460227 Pin, Male 2
303 4460909 Connector, Female - 12 Position 1
4460517 Socket, Female 8
4460466 Seal, Plug 6
4460915 Lock, Wedge 1
304 4461000 Connector, Strain Relief 1
Ref. C
4922924 LOAD SENSING HARNESS ASSEMBLIES
(DVL/DVSP/MVL/MSP MODELS) (NOT SHOWN)
401 Not Available Cable Assembly - Light/Alarm Harness (Plugs into Item 402)
(Purchase p/n 4922924)
4460424 Connector, Female - 2 Position 1
4460267 Pin, Male 2
402 Not Available Cable Assembly - Aux Output 1 to Light/Alarm Harness (Plugs
into Item 401) (Purchase p/n 4922924)
4460424 Connector, Female - 2 Position (To Aux Output 1) 1
4460226 Socket, Female 1
4460267 Pin, Male 1
4460320 Plug, Male - 2 Position (To Light/Alarm Harness) 1
4460226 Socket, Female 2
403 Not Available Cable Assembly - Tilt Plug to Platform Harness (Purchase p/n
4922924)
4460326 Plug, Male - 3 Position (To Tilt Plug) 1
4460226 Socket, Female 3
4460445 Connector, Female - 3 Position (To Platform Harness) 1
4460267 Pin, Male 3
404 Not Available Cable Assembly - Limit Switch Harness (Purchase p/n
4922924)
4460320 Plug, Male - 2 Position 1
4460226 Socket, Female 2
4360546 Switch, Limit 1
Ref. D
1
1
1
1
3124289 – JLG Lift – 3-5
FIGURE 3-1 PLATFORM SUPPORT & LOAD SENSING INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
3-6 – JLG Lift – 3124289
McConnellsburg PA. 17233-9533
3124289
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
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