JLG 3124288 User manual

Operation & Safety,
Service & Maintenance, &
Illustrated Parts Manual Supplement
JLG
LOAD
SENSING
SYSTEM
Scissors Lift Products
P/N
3124288
July 26, 2013
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INTRODUCTION
3124288 – JLG Lift – A-1
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 per-
sonnel pay strict attention to these warnings and precau-
tions 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 VIOLA-
TION.
The specific precautions to be observed during mainte-
nance 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 CON-
TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/
OPERATOR.
B HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high, potentially dangerous pres-
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of
the system.
CMAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAU-
TIONS 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 DISCONNECTED-
DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
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INTRODUCTION
A-2 – JLG Lift – 3124288
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
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3124288 – JLG Lift – i
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - 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
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ii – JLG Lift – 3124288
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
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3124288 – JLG Lift – iii
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
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iv – JLG Lift – 3124288
TABLE OF CONTENTS (Continued)
NOTES:
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SECTION 1 - ANALYZER OPERATION - ALL
3124288 – JLG Lift – 1-1
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 sec-
onds 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
2.
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 Per-
sonality settings and calibrate.
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SECTION 1 - ANALYZER OPERATION - ALL
1-2 – JLG Lift – 3124288
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 can-
not be accidentally altered. To change the access level,
the correct password must be entered. To enter the pass-
word, scroll to the ACCESS LEVEL menu. For example:
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the pass-
word.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
Continue using the arrow keys until all the remaining digits
of the password is shown.
Once the correct password is displayed, press ENTER.
The access level should display the following, if the pass-
word 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.
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SECTION 1 - ANALYZER OPERATION - ALL
3124288 – JLG Lift – 1-3
1.4 VIEWING & ADJUSTING PARAMETERS
USING THE HAND HELD ANALYZER
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
PERSONALITIES:
OVR DEBNCE 3.0s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular per-
sonality. 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:
DRIVE ACCEL 3 .0s
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SECTION 1 - ANALYZER OPERATION - ALL
1-4 – JLG Lift – 3124288
NOTES:
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SECTION 2 - OPERATION - (LE, MRT, RTS)
3124288 – JLG Lift – 2-1
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 con-
nect 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 back-
wards.
2. Power-up the Control System by turning the key to
the Platform or Ground position and pulling both
emergency stop buttons.
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 dis-
play EVERYTHING OK if the platform is not overloaded
and no difficulties are detected. Otherwise, the JLG Ana-
lyzer will display OVERLOADED.
In the event of difficulty, the user can press ENTER again
to display Logged Help, which is a record of the last 16
Fault Messages. The following table lists each Help/
Logged Message, the Flash Code (for each Fault, the
module will flash the two-digit code on its LED) triggered
by the Fault, and a Description of the Situation (cause).
Table 2-1. LSS Fault Codes (LE, MRT and RTS)
Help/Logged
Message
Flash
Code Description of Situation
Everything OK LED ON The "Normal" Help Message
<MIN CAL Calibration attempt Unsuccessful, Empty Platform appears to weigh too little. Improper Model Selection (Machine
Setup) may cause the LSS Module to expect the wrong Empty Platform Weight. This also may be caused by a damaged
sensor or associated wiring. Finally, this condition may occur if mechanical interference between the platform and sup-
port structure exists (all weight must transfer through sensors).
>MAX CAL Calibration attempt Unsuccessful, Empty Platform appears to weigh too much. This situation has the same root causes
as the "<MIN CAL" Fault Message.
BATT TOO LOW 4/1 Incoming Supply Voltage <9.0 Vdc. The control system’s battery voltage is too low due to excessive electrical load or
discharge.
BATT TOO HIGH 4/4 Incoming Supply Voltage >34.0 Vdc. The control system’s battery voltage is too high. This may be due to over-charg-
ing or improper charger operation.
C E L L # 1 E R R O R 8 / 1 C e l l # 1 ’ s B r i d g 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
or its wiring.
C E L L # 2 E R R O R 8 / 2 C e l l # 2 ’ s B r i d g 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
or its wiring.
C E L L # 3 E R R O R 8 / 3 C e l l # 3 ’ s B r i d g 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
or its wiring.
C E L L # 4 E R R O R 8 / 4 C e l l # 4 ’ s B r i d g 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
or its wiring.
WATCHDOG RST 9/1 Microprocessor’s Watchdog Timer Triggered. This is an indication that the LSS Module has been exposed to excessive
electrical noise, or has experienced a hardware difficulty.
EEPROM ERROR 9/2 Memory used to retain Personality/Machine Setup/Calibration has been corrupted and must be reset by verifying all
entries and re-calibrating.
NO CAL 9/3 Calibration has not been successfully completed. A new LSS Module will display this message until properly cali-
brated.
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SECTION 2 - OPERATION - (LE, MRT, RTS)
2-2 – JLG Lift – 3124288
INTERNAL ERR 9/9 Pin excitation <4.25 V. The sensors may be excessively loading the excitation supply, or the LSS Module may have
hardware difficulty.
High Side Driver Error. The load attached to OUT1 or OUT2 is shorted to battery or ground and has been detected by the
LSS module.
DRDY Interrupt from A/D missing. This may indicate an LSS Module hardware difficulty.
Table 2-1. LSS Fault Codes (LE, MRT and RTS)
Help/Logged
Message
Flash
Code Description of Situation
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SECTION 2 - OPERATION - (LE, MRT, RTS)
3124288 – JLG Lift – 2-3
2.3 DIAGNOSTIC MENU (LE, MRT & RTS)
The Diagnostic Load Menu is another troubleshooting tool
for the Load Sensing System. Sensor and status informa-
tion 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).
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 dis-
plays 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 infor-
mation presented.
Table 2-2. Diagnostic Menu Descriptions (LE, MRT & RTS)
Diagnostics Menu
(Displayed on Analyzer 1st Line)
Parameter (Displayed
on Analyzer 2nd Line)
Parameter Value
(Displayed on Analyzer 2nd
Line)
Description
PLTLOAD +XXXX LBS or Kg Displays (Total Measured Force – Empty Platform
Calibration)
PLTGROS +XXXX LBS or Kg Displays Total Measured Force (Sum of Pins 1 thru 4
LOAD)
OVERLOADED? Yes / No Displays Current LSS Module Overload Status
CELL 1:
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +XX.XXXX mV/V Displays Pin Reading in mV/V
INPUT +XX.XXXX mV Displays Pin Reading in mV
GAIN XXXX.X Displays calibration factor from pin
CELL 2:
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +XX.XXXX mV/V Displays Pin Reading in mV/V
INPUT +XX.XXXX mV Displays Pin Reading in mV
GAIN XXXX.X Displays calibration factor from pin
CELL 3:
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +XX.XXXX mV/V Displays Pin Reading in mV/V
INPUT +XX.XXXX mV Displays Pin Reading in mV
GAIN XXXX.X Displays calibration factor from pin
CELL 4:
LOAD +XXXX LBS or Kg Displays Calibrated Cell Reading in Current Units
RDG +XX.XXXX mV/V Displays Pin Reading in mV/V
INPUT +XX.XXXX mV Displays Pin Reading in mV
GAIN XXXX.X Displays calibration factor from pin
SYSTEM:
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
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SECTION 2 - OPERATION - (LE, MRT, RTS)
2-4 – JLG Lift – 3124288
MOTION #2 OFF / ON Status of Digital Input #2
MOTION #3* OFF / ON Status of Digital Input #3
BATTERY XX.XXV Displays Current Battery Voltage
EXCITE X.XXXXV Displays Load Pin Excitation Voltage
TEMP +/-XXX.X Deg C Display the Temperature Sensed by the LSS Module
for Scissor Pin Compensation
VERSIONS:
SOFTWARE PX.XX Displays LSS Module Software Version
HARDWARE XDisplay LSS Module Hardware Revision
ANALYZER VX.XXXX Displays Analyzer Software Version
Table 2-2. Diagnostic Menu Descriptions (LE, MRT & RTS)
Diagnostics Menu
(Displayed on Analyzer 1st Line)
Parameter (Displayed
on Analyzer 2nd Line)
Parameter Value
(Displayed on Analyzer 2nd
Line)
Description
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SECTION 2 - OPERATION - (LE, MRT, RTS)
3124288 – JLG Lift – 2-5
2.4 PERSONALITIES (LE, MRT & RTS)
NOTE: The following parameter adjust performance of the
Load Sensing System. All adjustments must be made
at access level 1 (33271).
THE SETTINGS UNDER THE FACTORY MENU OPTION
ARE UNIQUE TO EACH MODULE. THESE SETTINGS
ARE NOT TO BE ALTERED. IN THE EVENT THAT THESE
SETTINGS ARE ALTERED, CONTACT DISCOUNT-
EQUIPMENT WITH THE SERIAL NUMBER OF THE
MODULE.
Table 2-3. Personalities Menu Description (LE, MRT, RTS)
Personalities
(Displayed on
Analyzer 1st line)
Parameter (Displayed
On Analyzer 2nd line) Description 4069LE 3369LE 500RTS 260MRT
OVERLD XXXX
LBS (KGS)
Displays/adjusts the overload limit for this
AWP
550 LBS
(378 KGS)
1042 LBS
(473 KGS)
No
Extensions-
2628 LBS
(1192 KGS)
Single or
Dual
Extensions
2083 LBS
(945 KGS)
MegaDeck-
1574 LBS
(714 KGS)
1320 LBS
(599 KGS)
ACC’Y XXXX LBS
(KGS)
Displays/adjusts a de-rating for
Accessories
0 LBS
(0KGS)
0 LBS
(0KGS)
0 LBS
(0KGS)
0 LBS
(0KGS)
MTN DELAY XS Displays/adjusts the delay between motion
ceasing and evaluation of overload 2 SEC 2 SEC 2 SEC 2 SEC
OVR DBNCE XS Displays/adjusts the de-bounce delay
before an overload 3 SEC 3 SEC 3 SEC 3 SEC
OVR HOLD XS Displays/adjusts the minimum delay
before an overload can be released. 5 SEC 5 SEC 5 SEC 5 SEC
FACTORY #1 GAIN
X.XXXX
Displays/calibrates the LSS Module analog
channel gain
X
#1 ZERO
+X.XXXX mV
Displays/calibrates the LSS Module analog
channel offset.
X
#2 GAIN
X.XXXX
Displays/calibrates the LSS Module analog
channel gain
X
#2 ZERO
+X.XXXX mV
Displays/calibrates the LSS Module analog
channel offset
X
#3 GAIN
X.XXXX
Displays/calibrates the LSS Module analog
channel gain
X
#3ZERO
+X.XXXX mV
Displays/calibrates the LSS Module analog
channel offset
X
#4 GAIN
X.XXXX
Displays/calibrates the LSS Module analog
channel gain
X
#4 ZERO
+X.XXXX mV
Displays/calibrates the LSS Module analog
channel offset
X
EX GAIN
X.XXXX
Displays/calibrates the LSS Module excita-
tion measurement gain
X
TEMP OFFS
+/- XXX.X
Displays/calibrates the LSS Module internal
temp sensor
X
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SECTION 2 - OPERATION - (LE, MRT, RTS)
2-6 – JLG Lift – 3124288
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 kilo-
grams). 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 sup-
pressed).
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 dis-
plays.
The following table details the structure of the Machine
Setup Menu, and describes the meaning of each parame-
ter.
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.
Table 2-4. Machine Setup Menu
Parameter
(Displayed on
Analyzer 2nd
Line)
Parameter Value
(Displayed on
Analyzer 2nd Line)
Description
MODEL:
=BOOM LIFT
=4069LE
=3369LE
=500RTS
=260MRT
=Scissor
Displays/adjusts Model Selec-
tion. Must be set to proper
model for this application.
(Scissor available after soft-
ware V7.00)
UNITS: =LBS
=Kg
Displays/adjusts global force
units
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SECTION 2 - OPERATION - (LE, MRT, RTS)
3124288 – JLG Lift – 2-7
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 cali-
bration value. If successful, the Analyzer will show the fol-
lowing:
CALIBRATE:
COMPLETE
If the empty platform weight is less than minimum calibra-
tion 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 cali-
bration value, the calibration attempt will be unsuccessful
and the Analyzer will show the following:
CALIBRATE:
> MAX CAL
Table 2-5. Calibration Values
MODELS 4069LE 3969LE 500RTS 260MRT
Minimum Cali-
bration Value
850 lb
(385 kg)
850 lb
(385 kg)
1100 lb
(499 kg)
750 lb
(340 kg)
Maximum Cali-
bration Value
1425 lb
(646 kg)
1425 lb
(646 kg)
2950 lb
(1338 kg)
1250 lb
(567 kg)
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