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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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Содержание 3124288

Страница 1: ...fety Service Maintenance Illustrated Parts Manual Supplement JLG LOAD SENSING SYSTEM Scissors Lift Products P N 3124288 July 26 2013 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u...

Страница 2: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

Страница 3: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 4: ...TURER 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 hy...

Страница 5: ...sed 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 Re...

Страница 6: ...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 Conn...

Страница 7: ...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...

Страница 8: ...ommunication 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 Conn...

Страница 9: ...iv JLG Lift 3124288 TABLE OF CONTENTS Continued NOTES G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 10: ...ed 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 Calib...

Страница 11: ...VEL 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 e...

Страница 12: ...um 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...

Страница 13: ...SECTION 1 ANALYZER OPERATION ALL 1 4 JLG Lift 3124288 NOTES G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 14: ...Situation EverythingOK LEDON The Normal HelpMessage MINCAL Calibration attemptUnsuccessful Empty Platformappearsto weightoolittle ImproperModelSelection Machine Setup maycausetheLSSModuletoexpectthew...

Страница 15: ...re difficulty HighSideDriverError TheloadattachedtoOUT1orOUT2isshortedtobatteryorgroundandhasbeendetectedbythe LSSmodule DRDY Interrupt from A Dmissing This mayindicateanLSS Modulehardwaredifficulty T...

Страница 16: ...layed on Analyzer 1st Line Parameter Displayed on Analyzer 2nd Line Parameter Value Displayed on Analyzer 2nd Line Description PLTLOAD XXXXLBSorKg Displays TotalMeasuredForce EmptyPlatform Calibration...

Страница 17: ...he LSS Module forScissor Pin Compensation VERSIONS SOFTWARE PX XX DisplaysLSS Module SoftwareVersion HARDWARE X DisplayLSSModuleHardwareRevision ANALYZER VX XXXX DisplaysAnalyzerSoftwareVersion Table...

Страница 18: ...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...

Страница 19: ...chine 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...

Страница 20: ...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...

Страница 21: ...c r e t a r y A C C Y X X X X L B S K G V E R S I O N S 2 G A I N X X X X X 1 Z E R O X X X X X 1 G A I N X X X X X 2 Z E R O X X X X X 1 Z E R O X X X X X 1 G A I N X X X X X 3 Z E R O X X X X X 3 G...

Страница 22: ...accurately indicate overload by the De Rating factor Example Consider that of the Easi Cladder with a De Rating of 300 lbs 136 kg mounted on a 500RTS Without De Rating the Load Sensing System will dec...

Страница 23: ...SECTION 2 OPERATION LE MRT RTS 2 10 JLG Lift 3124288 NOTES G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 24: ...ontrolmay be prevented depending on machine BATTERY TOOHIGH 4 4 IncomingSupplyVoltage 34 0Vdc Thecontrolsystem sbatteryvoltageistoohigh Thismaybeduetoover charg ing orimproperchargeroperation BATTTOO...

Страница 25: ...ORKSTATION IN THE SKY ACCESSORIES IN THIS SECTION WITH REGARD TO SETTING THE ACCY PERSON ALITIES Table 3 2 Diagnostic Menu Descriptions ES RT Diagnostics Menu Displayed on Analyzer 1st Line Parameter...

Страница 26: ...mpty 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...

Страница 27: ...owing 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...

Страница 28: ...r e t a r y A C C Y X X X X L B S K G V E R S I O N S 2 G A I N X X X X X 1 Z E R O X X X X X 1 G A I N X X X X X 2 Z E R O X X X X X 1 Z E R O X X X X X 1 G A I N X X X X X 3 Z E R O X X X X X 3 G A...

Страница 29: ...SECTION 3 OPERATION ES RT 3 6 JLG Lift 3124288 NOTES G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 30: ...prevented andfunctionsfromGround Controlmaybe pre vented dependingonmachineconfiguration Marketsotherthan Japan Forthe Japanese Market only Lift Up isprevented and Drive atcreepspeed is allowedin thes...

Страница 31: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

Страница 32: ...yzer 2nd Line DESCRIPTION LOAD OVERLOADED Yes No Displaysthe current LSS state PRES1 xxxxPSI Displaysthe actualpressurereading fromPres sure Transducer 1 PRES2 xxxxPSI Displaysthe actualpressurereadin...

Страница 33: ...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...

Страница 34: ...imum height is acceptable the Control System will record the sensors value and Analyzer will display the following CAL ANGLE LOWER TO STOWED If the Angle Sensors range from stowed to maximum height is...

Страница 35: ...ANGLE SENSOR CALIBRATION FAILURE Displayed on Analyzer 2nd Line DESCRIPTION CHECK MAXNOTINRANGE The AngleSensorsupperlimitis notaccept able Itmustfall within 35counts of210 counts Check the Angle Sens...

Страница 36: ...es maximum eleva tion CAL LOAD LIFT TO MAX ELEV Pressing the Enter key again will make the Analyzer dis play the following which means engage lift down until the platform becomes stowed CAL LOAD LOWER...

Страница 37: ...ns menu and enter the Angle submenu to perform Angle Sensor calibration The Angle sensor must be calibrated before Load calibration can occur PLATNOTSTOWED Themachines platformis not stowed Ensure tha...

Страница 38: ...SECTION 4 OPERATION RS 4 8 JLG Lift 3124288 NOTES G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 39: ...rce for the platform is applied through them for measurement The four Shear Pin Load Cells plug directly into the LSS Module The Wire Harness con nects the LSS Module to the Host Control System 1 2 3...

Страница 40: ...erence 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 entere...

Страница 41: ...switch 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 sec...

Страница 42: ...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 fail...

Страница 43: ...500RTS 260MRT or SCISSOR Improper selection may lead the LSS Module to expect dif ferent empty platform weights 3 The calibration difficulty may be a result of a Measurement Performance issue Review...

Страница 44: ...rmal 2 Wiring leading to one of the Shear Pin Load Cells is damaged Examine each sen sor s reading using the JLG Analyzer Proceed to the DIAGNOSTICS CELL 1 4 LOAD displays and determine if the reading...

Страница 45: ...y 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 se...

Страница 46: ...the LSS Module and the Host Control Sys tem is shorted The Platform Module s J1 20 is an input and it connected to the J1 5 output on the LSS Module To examine the status of this signal plug the JLG...

Страница 47: ...olor number and ter minal 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 p...

Страница 48: ...zer Pin1 approx 12V 2 TX RS 232forJLGAnalyzer AnalyzerPin3 3 TRP1 120OhmCANbusTerminator 4 CANH 1 CANbusInterfaceHigh 5 CANS 1 CANbusShieldTermination NotsameasGND 6 CANH 2 ConnectstoCANH 1 7 CANL 2 C...

Страница 49: ...SECTION 5 SERVICE LE MRT RTS ES RT 3124288 JLG Lift 5 11 Figure 5 3 260MRT Wiring Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 50: ...SECTION 5 SERVICE LE MRT RTS ES RT 5 12 JLG Lift 3124288 Figure 5 4 M3369 M4069 3369LE 4069LE Wiring Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 51: ...SECTION 5 SERVICE LE MRT RTS ES RT 3124288 JLG Lift 5 13 Figure 5 5 500RTS Wiring Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 52: ...SECTION 5 SERVICE LE MRT RTS ES RT 5 14 JLG Lift 3124288 Figure 5 6 ES Wiring Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 53: ...SECTION 5 SERVICE LE MRT RTS ES RT 3124288 JLG Lift 5 15 Figure 5 7 RT Wiring Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 54: ...SECTION 5 SERVICE LE MRT RTS ES RT 5 16 JLG Lift 3124288 NOTES G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 55: ...alyzer 5 Navigate to the ACCESS LEVEL menu on the Ana lyzer 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 an...

Страница 56: ...Panel until the plat form 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 activat...

Страница 57: ...the step LOWER TO STOWED during Angle Calibration 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...

Страница 58: ...rload with 120 load placed in the platform per form an ANGLE calibration followed by a LOAD calibration as specified by the Calibration procedures listed in this document 3 If a fault is displayed ref...

Страница 59: ...he 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 Reconn...

Страница 60: ...ety prop 4 Lower the platform on to the safety prop and con tinue to engage lift down for 1 second after the plat form makes contact with the safety prop 5 Disconnect power at the batteries 6 Disconne...

Страница 61: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

Страница 62: ...IGNAL DESCRIPTION 5 CANL CANbusLow 6 CANH CANbusHigh 15 CANS CANbusShield 22 NOVL NagativeforOverloadLamp Low SideDriver Table 6 6 Angle Sensor Connector Pinout RS PIN SIGNAL DESCRIPTION 1 GND AngleSe...

Страница 63: ...ES 5 6 15 22 CANL CANH CANS NOVL A B C 5V GND PRES1 A B C 5V GND PRES2 1 2 3 GND PWR CANL 4 5 CANH NC 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...

Страница 64: ...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 SENSIN...

Страница 65: ...OCK TO ANALYZER GROUND CONTROL BOX INDICATOR LIGHT TO LOAD SENSE POWER SUPPLY PLATFORM CONTROL BOX INDICATOR LIGHT 7 7 7 7 29 29 29 29 29 29 29 29 18 18 18 18 20 20 20 20 20A 20A 20A 20A 20B 20B 34B 3...

Страница 66: ...nt 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 Optio...

Страница 67: ...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 3369...

Страница 68: ...LG Lift 7 5 FIGURE 7 1 LOAD SENSING SYSTEM INSTALLATION 260MRT M3369 M4069 3369LE 4069LE FIG ITEM PART NUMBER DESCRIPTION QTY REV G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r...

Страница 69: ...7 6 JLG Lift 3124288 FIGURE 7 2 LOAD SENSING SYSTEM INSTALLATION 500RTS G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 70: ...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...

Страница 71: ...LOCK LEFT REAR PLATFORM SLIDE BLOCK RIGHT FRONT PLATFORM SLIDE BLOCK RIGHT REAR PLATFORM SLIDE BLOCK TO ANALYZER TO LOAD SENSE POWER SUPPLY 5 18 18 5 18 18 4 4 7 7 7 7 8 8 8 8 8A 8A 8A 8A 6 14 10 8B 8...

Страница 72: ...1200008265 to Present Ref B 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...

Страница 73: ...lgium 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 U...

Страница 74: ...Lift 7 11 FIGURE 7 3 LOAD SENSING SYSTEM INSTALLATION 1930ES 2032ES 2630ES 2646ES 3246ES FIG ITEM PART NUMBER DESCRIPTION QTY REV G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r...

Страница 75: ...4 LOAD SENSING SYSTEM INSTALLATION 6RS 10RS 1932RS 3248RS 35 35 6RS 1932RS 6RS 1932RS SHOWN 10RS 3248RS NOT SHOWN TYPICAL 10S 3248RS 45B 45A 45 40 43 G o t o D i s c o u n t E q u i p m e n t c o m t...

Страница 76: ...290607 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...

Страница 77: ...RONT PLATFORM SLIDE BLOCK RIGHT REAR PLATFORM SLIDE BLOCK MODULE RIGHT FRONT OF MACHINE TO ANALYZER PLATFORM MODULE TO CLADDER ACCESSORY 4 4 4 4 5 5 5 5 5 15 16A 17A 17 17 14E 14D 14A 14C 14 14B 5 5 3...

Страница 78: ...C 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...

Страница 79: ...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 FIGURE 7 5 LOAD SENSING SYSTEM INSTALLATION 3394RT...

Страница 80: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

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