JLG 3124288 Manual
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JLG 3124288 Manual

JLG 3124288 Manual

Load sensing system
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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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Summary of Contents for JLG 3124288

  • Page 1 Operation & Safety, Service & Maintenance, & Illustrated Parts Manual Supplement LOAD SENSING SYSTEM Scissors Lift Products 3124288 July 26, 2013...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 4: Bhydraulic System Safety

    • USE ONLY APPROVED, NONFLAMMABLE CLEANING operate at extremely high, potentially dangerous pres- SOLVENTS. sures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. 3124288 – JLG Lift –...
  • Page 5 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 – JLG Lift – 3124288...

  • Page 6: Table Of Contents

    Connecting the JLG Control System Analyzer (ES & RT) .......3-1...
  • Page 7 LSS Troubleshooting Chart - Calibration ..........5-5 – JLG Lift –...
  • Page 8 Pressure Transducer Connector Pinout (RS) .........6-7 3124288 – JLG Lift –...
  • Page 9 TABLE OF CONTENTS (Continued) NOTES: – JLG Lift – 3124288...

  • Page 10: Section 1. Analyzer Operation - All

    Calibration of the Load Sensing System is performed by changed. You may only view Personality settings while in connecting the JLG Analyzer (Analyzer Kit, JLG part no. Access Level 2. Access Level 1 is required to change Per- 2901443). All calibration procedures are menu driven sonality settings and calibrate.

  • Page 11: Changing The Access Level Of The Hand Held Analyzer

    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. – JLG Lift – 3124288...

  • Page 12: Viewing & Adjusting Parameters Using The Hand Held Analyzer

    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. 3124288 – JLG Lift –...
  • Page 13 SECTION 1 - ANALYZER OPERATION - ALL NOTES: – JLG Lift – 3124288...

  • Page 14: Section 2. Operation - (Le, Mrt, Rts)

    THE HOST CONTROL SYSTEM. 1. Connect the cable supplied with the Analyzer to the When accessing the Help Menu, the JLG Analyzer will dis- LSS Module located beneath the platform and con- play EVERYTHING OK if the platform is not overloaded nect the remaining end of the cable to the analyzer.
  • Page 15 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. – JLG Lift – 3124288...

  • Page 16: Diagnostic Menu (Le, Mrt & Rts)

    State of Overload Status Digital Output OFF / ON WARNING State of Warning Digital Output OFF / ON MOT INHIBIT Status of Internal Motion Inhibit Flag NO / YES MOTION #1 Status of Digital Input #1 OFF / ON 3124288 – JLG Lift –...
  • Page 17 Display the Temperature Sensed by the LSS Module +/-XXX.X Deg C for Scissor Pin Compensation VERSIONS: SOFTWARE Displays LSS Module Software Version PX.XX HARDWARE Display LSS Module Hardware Revision ANALYZER Displays Analyzer Software Version VX.XXXX – JLG Lift – 3124288...

  • Page 18: Personalities (Le, Mrt & Rts)

    #4 ZERO Displays/calibrates the LSS Module analog +X.XXXX mV channel offset EX GAIN Displays/calibrates the LSS Module excita- X.XXXX tion measurement gain TEMP OFFS Displays/calibrates the LSS Module internal +/- XXX.X temp sensor 3124288 – JLG Lift –...

  • Page 19: 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, To access the Calibration Menu, use the LEFT and RIGHT and select the desired force units (i.e. pounds or kilo- Arrow keys to select CALIBRATION from the Top Level grams).
  • Page 20 750 lb bration Value (385 kg) (385 kg) (499 kg) (340 kg) Maximum Cali- 1425 lb 1425 lb 2950 lb 1250 lb bration Value (646 kg) (646 kg) (1338 kg) (567 kg) CALIBRATE: > MAX CAL 3124288 – JLG Lift –...
  • Page 21 SECTION 2 - OPERATION - (LE, MRT, RTS) – JLG Lift – 3124288...

  • Page 22: Jlg Workstation In The Sky™ Accessories

    Overload with less platform load (by the amount of the De- tion. Rating). A De-Rating is provided for JLG Sky Accessories via decal and/or the JLG Workstation in the Sky Accessory Man- ual. This De-Rating must be entered into the LSS Mod- ule’s ACC’Y Personality to cause the system to accurately...
  • Page 23 SECTION 2 - OPERATION - (LE, MRT, RTS) NOTES: 2-10 – JLG Lift – 3124288...

  • Page 24: Section 3. Operation - (Es, Rt)

    RT. Connect the remaining end of the cable to the analyzer. When accessing the Help Menu, the JLG Analyzer will dis- NOTE: The cable has a four-pin connector at each end of play EVERYTHING OK if the platform is not overloaded the cable;...

  • Page 25: Diagnostic Menu (Es & Rt)

    VX.XXXX 3.4 PERSONALITIES (ES & RT) The following parameter in the PERSONALITIES, LOAD REFER TO JLG WORKSTATION IN THE SKY™ ACCESSORIES IN menu adjust performance of the LSS. All adjustments THIS SECTION WITH REGARD TO SETTING THE ACCY PERSON- must be made in Access Level 1 (33271).

  • Page 26: Machine Setup Menu (Es & Rt)

    Displays/adjusts the LOAD: 1 = CUTOUT PLT LSS Module 2 =CUTOUT ALL 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 –...
  • Page 27 Analyzer will show the following: CALIBRATE: COMPLETE Table 3-5. Calibration Values MODELS 45 KG 225 KG Minimum Calibration Value (99 LB) (496 LB) 275 KG 1020KG Maximum Calibration Value (606 LB) (2249 LB) CALIBRATE: > MAX CAL – JLG Lift – 3124288...
  • Page 28 SECTION 3 - OPERATION - (ES, RT) 3124288 – JLG Lift –...
  • Page 29 SECTION 3 - OPERATION - (ES, RT) NOTES: – JLG Lift – 3124288...

  • Page 30: Section 4 - Operation - (Rs)

    3. Connect the cable supplied with the Analyzer to the mating 4 pin connector that was just disconnected. When accessing the Help Menu, the JLG Analyzer will dis- play EVERYTHING OK if the platform is not overloaded NOTE: The cable has a four-pin connector at each end of and no difficulties are detected.
  • Page 31 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 32: Diagnostic Menu (Rs)

    Displays the angle sensors MAXANGLE (max ele- vation) value based on angle sensor calibration. ANGLERANGE Displays the difference between MAXANGLE and MINANGLE. ANGLERANGE = MAXANGLE - MINANGLE. ANGLE Displays the actual angle sensor count value at all times. – JLG Lift – 3124288...

  • Page 33: Personalities Menu (Rs)

    Upon entry to the Calibration, ANGLE Menu, the analyzer will display: CAL ANGLE: YES:ENTER NO:ESC 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 –...
  • Page 34 COMPLETE! 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. CAL ANGLE: LOWER TO STOWED CAL ANGLE: LOWER TO STOWED – JLG Lift – 3124288...

  • Page 35: Load Sensing System Calibration (Rs Only)

    Pressing the ESC key at any time will return the user to the top level menu and not disturb the prior calibration infor- mation. Pressing the Enter key will ensure that appropriate Cali- bration Weight, 110% rated load, has been placed in the 3124288 – JLG Lift –...
  • Page 36 If the Load Calibration is successful the Analyzer will dis- ground panel until the platform reaches maximum eleva- play the following. tion. CAL LOAD: COMPLETE! CAL LOAD: LIFT TO MAX ELEV CAL LOAD: CAL LOAD: COMPLETE! LIFT TO MAX ELEV – JLG Lift – 3124288...
  • Page 37 • The technician let go of the lift up switch tion. before the machine reached maximum ele- vation during "CAL LOAD: LIFT TO MAX ELEV". CAL FAIL The technician has pressed ESC on the Ana- lyzer during the calibration routine. 3124288 – JLG Lift –...
  • Page 38 SECTION 4 - OPERATION - (RS) NOTES: – JLG Lift – 3124288...

  • Page 39: Section 5. Service - (Le, Mrt, Rts, Es, Rt)

    6. Rear Left Load Cell - J7 3. System Interface Communication - J2 7. Front Right Load Cell - J6 4. Indicator Light 8. Front Left Load Cell - J5 Figure 5-1. Load Sense Module 3124288 – JLG Lift –...

  • Page 40: 5.2 Calibration

    ENTER. Press ESC to abort a calibration or Procedure ENTER to calibrate (tare). If successful, the Analyzer 1. Plug the JLG Analyzer into the LSS Module on the will display “COMPLETE”. If unsuccessful, a mes- LE, MRT and RTS or the Host Control System on the sage will be displayed that will help lead to a resolu- ES and RT and enter the Access Level 1 Password.
  • Page 41 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. 3124288 – JLG Lift –...

  • Page 42: 5.3 Troubleshooting

    Difficulty Possible Resolution JLG Analyzer does not display The JLG Analyzer is failing to communicate with the LSS Module, but the LSS Module is “HELP: PRESS ENTER” when powered (indicated by module’s LED). Investigate JLG Analyzer serial communication and connected to LSS Module’s power supply connections.
  • Page 43 1. Tools, debris, or customer-installed accessories have not been removed before cal- Calibrate. ibration. The LSS Module must tare an empty platform and its optional JLG Acces- sories. 2. The wrong Model Selection was made under the LSS Module’s MACHINE SETUP , MODEL.
  • Page 44 Also, examined each Shear Pin Load NOTICS, PLTLOAD) are unsta- Cell’s readings via the JLG Analyzer. Proceed to the DIAGNOSTICS, CELL 1-4, LOAD ble by more than +2lbs (±1kg) displays and determine if the readings are reasonable. Note that it is possible to have...
  • Page 45 7. The LSS Module is suspect. Interchange the Shear Pin Load Cell connections (J5- J8) 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.
  • Page 46 The Platform Module’s J1-20 is an input, and it connected to the J1- 5 output on the LSS Module To examine the status of this signal, plug the JLG Ana- lyzer into the Host Control System, enter the Access Level 1 password (33271), and examine the DIAGNOSTICS, SYSTEM, LOAD display.
  • Page 47 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.

  • Page 48: Lss Module Load Cell Connector Pinout (J5, J6, J7, J8)

    Pinout (J5, J6, J7, J8) Signal Description APWR Pre-Regulated Supply for JLG Analyzer (Analyzer Pin 1; approx. 12V) RS-232 for JLG Analyzer (Analyzer Pin 3) TRP1 120 Ohm CANbus Terminator CANH-1 CANbus Interface High CANS-1 CANbus Shield Termination (Not same as GND)

  • Page 49: 260Mrt Wiring Diagram

    SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT) Figure 5-3. 260MRT Wiring Diagram 3124288 – JLG Lift – 5-11...

  • Page 50: M3369/M4069 & 3369Le/4069Le Wiring Diagram

    SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT) Figure 5-4. M3369/M4069 & 3369LE/4069LE Wiring Diagram 5-12 – JLG Lift – 3124288...

  • Page 51: 500Rts Wiring Diagram

    SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT) Figure 5-5. 500RTS Wiring Diagram 3124288 – JLG Lift – 5-13...

  • Page 52: Wiring Diagram

    SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT) Figure 5-6. ES Wiring Diagram 5-14 – JLG Lift – 3124288...

  • Page 53: Rt Wiring Diagram

    SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT) Figure 5-7. RT Wiring Diagram 3124288 – JLG Lift – 5-15...
  • Page 54 SECTION 5 - SERVICE - (LE, MRT, RTS, ES, RT) NOTES: 5-16 – JLG Lift – 3124288...

  • Page 55: Section 6. Service - (Rs)

    6. Remove the orange panel on the ground control key switch trip point. switch side of the machine. 7. Disconnect the MDI display and connect the JLG Angle Sensor Calibration Procedure (RS) Analyzer. 1. Ensure the batteries are fully charged and the 8.

  • Page 56: Testing And Evaluation (Rs)

    Visual and Audible Warnings are not active. 1932RS/6RS 4.92 - 8.20 ft. (1.5 - 2.5m) Engage lift up from the Ground Panel until the plat- form reaches maximum elevation, and then engage 3248RS/10RS 8.20 - 11.48 ft. (2.5 - 3.5m) – JLG Lift – 3124288...

  • Page 57: Lss Troubleshooting (Rs)

    Table 6-3. LSS Troubleshooting - RS PROBLEM POSSIBLE RESOLUTION JLG Analyzer displays "MAX NOT IN The Angle Sensor’s upper limit is not acceptable. The Angle Sensor’s reading RANGE" after the step "LIFT TO MAX" must fall within +/- 35 counts of 210 counts when the platform is at maximum ele- during Angle Calibration vation.
  • Page 58 The Control at the Platform Control positions are prevented. 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"...

  • Page 59: Lss Component Removal/Installation (Rs)

    5. Lower the platform to the stowed position. 6. This completes pressure transducer repair. Figure 6-2. LSS Pressure Transducer Location - 3248RS/10RS 1. Ports On Bottom of Cylinder 3. Harness Connectors 2. Pressure Transducers 3124288 – JLG Lift –...

  • Page 60: 10Rs Angle Sensor Removal (Rs)

    2. LSS Scissor Arm Angle Sensor (rear plate shown cutaway) 2. LSS Scissor Arm Angle Switch (scissor arms shown cutaway) 3. Platform Entry Ladder 3. Platform Entry Ladder Figure 6-3. LSS - Scissor Arm Angle Sensor - (RS) – JLG Lift – 3124288...
  • Page 61 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 62: Lss Connector Pin Assignments (Rs)

    (RS) SIGNAL DESCRIPTION SIGNAL DESCRIPTION CANL CANbus Low Pressure Transducer Power (+5V) CANH CANbus High Pressure Transducer Ground CANS CANbus Shield Pressure Transducer Analog Output (0 - 5V) NOVL Nagative for Overload Lamp (Low-Side Driver) 3124288 – JLG Lift –...

  • Page 63: Lss - Electrical Component Schematic - (Rs)

    NOVL SHIELD CANS CANH CANL PRES2 WHT 61 GND NPRES WHT 60 5V SEN PPRES WHT 59 PRES2 PRES 2 WHT 58 PRES1 PRES 1 PRES1 Figure 6-4. LSS - Electrical Component Schematic - (RS) – JLG Lift – 3124288...

  • Page 64: Section 7. Parts

    LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/3248RS) ....7-12 LOAD SENSING SYSTEM INSTALLATION (34694RT/4394RT) ......7-14 – JLG Lift – 3124288...
  • Page 65 LEFT REAR PLATFORM LE MACHINES SLIDE BLOCK LE MACHINES LE MACHINES LE MACHINES RIGHT REAR PLATFORM SLIDE BLOCK LE MACHINES MRT MACHINES ANALYZER PLATFORM CONTROL INDICATOR LIGHT GROUND LOAD CONTROL SENSE POWER INDICATOR SUPPLY LIGHT – JLG Lift – 3124288...
  • Page 66 Plug, Male 12 Position 4460465 Socket, Female 4460466 Seal, Plug 0840055 Boot 4460761 Connector, Female 4 Position 4460294 Pin, Male Main Load Sensing Harness 4922915 260MRT (Prior to S/N 0200193881) 4922903 E/M3369/4069LE (Prior to S/N 0200152398) – JLG Lift – 3124288...

  • Page 67: Load Sensing System Installation (260Mrt, M3369/M4069 & 3369Le/4069Le)

    Pin, Male SCISSOR ARMS INSTALLATIONS WITH LSS (LE ONLY) Ref. 1001110710 260MRT Ref. 0275525 3369LE Ref. 0275526 4069LE Ref. Load Sensing Harness Options: 4922915 260MRT (S/N 0200193881 to Present) 4922903 E/M3369/4069LE (S/N 0200152398 to Present) – JLG Lift – 3124288...
  • Page 68 FIGURE 7-1. LOAD SENSING SYSTEM INSTALLATION (260MRT, M3369/M4069 & 3369LE/4069LE) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. – JLG Lift – 3124288...

  • Page 69: Load Sensing System Installation (500Rts)

    FIGURE 7-2. LOAD SENSING SYSTEM INSTALLATION (500RTS) – JLG Lift – 3124288...
  • Page 70 Plug, Male 12 Position 4460465 Socket, Female 4460466 Seal, Plug 0840055 Boot 1061021 Cable, Extension Not Available Plug, Male 6 Position Not Available Socket, Female Not Available Connector, Female 6 Position Not Available Pin, Male – JLG Lift – 3124288...

  • Page 71: Load Sensing System Installation (1930Es/2032Es/2630Es/ 2646Es/3246Es)

    FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES) LEFT FRONT PLATFORM SLIDE BLOCK RIGHT FRONT PLATFORM SLIDE BLOCK LEFT REAR PLATFORM SLIDE BLOCK RIGHT REAR PLATFORM SLIDE BLOCK LOAD SENSE POWER SUPPLY ANALYZER – JLG Lift – 3124288...
  • Page 72 Module to Analyzer Harness Options: USA Built Machines: 4922908 Prior to S/N 0200150266 4923228 S/N 0200150266 to Present Belgium Built Machines: 4922908 Prior to S/N 1200007882 4923228 S/N 1200007882 to Present 4460761 Connector, Female 4 Position 4460294 Pin, Male – JLG Lift – 3124288...
  • Page 73 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) 3290606 Nut M6 4812000 Flatwasher 10mm 0100048 Grease, Dielectric (Not Shown) 7-10 – JLG Lift – 3124288...
  • Page 74 FIGURE 7-3. LOAD SENSING SYSTEM INSTALLATION (1930ES/2032ES/2630ES/ 2646ES/3246ES) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. – JLG Lift – 3124288 7-11...
  • Page 75 FIGURE 7-4. LOAD SENSING SYSTEM INSTALLATION (6RS/10RS/1932RS/ 3248RS) 10S/3248RS 6RS/1932RS 6RS/1932RS (SHOWN) 10RS/3248RS (NOT SHOWN - TYPICAL) 7-12 – JLG Lift – 3124288...
  • Page 76 Not Used 3290405 Locknut M4 41 to 42 Not Used 4031512 Capscrew m4 x 40mm Not Used 1001151800 Sensor, Angle 70004167 70004168 Pin, Dowel See Note Harness (Note: Refer to Model Specific Parts Manual) – JLG Lift – 3124288 7-13...
  • Page 77 FIGURE 7-5. LOAD SENSING SYSTEM INSTALLATION (3394RT/4394RT) LEFT FRONT PLATFORM SLIDE BLOCK RIGHT FRONT PLATFORM SLIDE BLOCK LEFT REAR PLATFORM SLIDE BLOCK RIGHT REAR PLATFORM SLIDE BLOCK MODULE RIGHT FRONT MACHINE CLADDER ACCESSORY PLATFORM MODULE ANALYZER 7-14 – JLG Lift – 3124288...

  • Page 78: Load Sensing System Installation (3394Rt/4394Rt)

    Not Available Plug, Male 6 Position Not Available Socket, Female Not Available Connector, Female 6 Position Not Available Pin, Male 1061021 Cable, Extension (3 Meter) Not Available Plug, Male 6 Position Not Available Socket, Female – JLG Lift – 3124288 7-15...
  • Page 79 Pin, Male 18 to 19 Not Used 4240033 Tie-Strap (Not Shown) Not Used Bolt Options: 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...
  • Page 80 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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