This document is a comprehensive manual for the JLG Load Sensing System (LSS) used in Scissors Lift Products, specifically covering operation, safety, service, and parts. It is an Illustrated Parts Manual Supplement, indicating it provides additional details or updates to a primary manual.
Function Description:
The JLG Load Sensing System (LSS) is designed to monitor the load on the platform of JLG Scissors Lift Products. Its primary function is to ensure safe operation by preventing overloading of the platform. The system uses multiple shear pin load cells (sensors) to measure the weight on the platform. If an overload condition is detected, the system triggers visual and audible warnings and may prevent further machine operation, such as lift-up or drive functions, to ensure safety. The LSS is configured for proper operation with JLG Sky™ Accessories, and its calibration is performed with the Accessory mounted on the platform. The system also incorporates angle sensors to monitor the platform's angle, which is crucial for stability and safe operation, especially on uneven terrain.
Important Technical Specifications:
The manual references various JLG Scissors Lift models, including 260MRT, M3369/M4069, 3369LE/4069LE, 500RTS, 1930ES/2032ES/2630ES/2646ES/3246ES, 6RS/10RS/1932RS/3248RS, and 3394RT/4394RT.
The LSS module is connected to the host control system via a wiring harness. It includes multiple load cells (J5, J6, J7, J8) and an analyzer connector (J1-Black or J2-Blue).
Calibration values for different models are provided, for example:
- 4069LE: Minimum Calibration Value: 850 lb (386 kg), Maximum Calibration Value: 1425 lb (646 kg)
- 3369LE: Minimum Calibration Value: 850 lb (386 kg), Maximum Calibration Value: 1425 lb (646 kg)
- 500RTS: Minimum Calibration Value: 1100 lb (499 kg), Maximum Calibration Value: 2950 lb (1338 kg)
- 260MRT: Minimum Calibration Value: 750 lb (340 kg), Maximum Calibration Value: 1250 lb (567 kg)
The system also monitors pressure transducer inputs (0-5V) and angle sensor inputs (10-30V).
Electrical specifications include:
- Positive Power Supply from Host Control System (12-24V)
- Negative Power Supply from Host Control System (0V)
- Pre-regulated Supply for JLG Analyzer (approx. 12V)
- CANbus Low and High signals for communication.
- Overload Indicator Output (Normal=VBAT / Overloaded=VBAT for 5 Sec, 0V for 2 Sec)
The manual also details various bolt options and locknuts for installation, with specific part numbers and quantities for different models.
Usage Features:
The LSS is managed through a handheld analyzer, which allows technicians to access various menus for operation, diagnostics, and calibration.
- Analyzer Operation: The analyzer displays menus such as "MENU: ACCESS LEVEL" to control access, "PERSONALITIES" to adjust performance, and "DIAGNOSTICS" to view system parameters and fault codes.
- Access Levels: The system uses access levels (e.g., Access Level 1, Access Level 2) to control who can modify settings. Passwords are required to change access levels.
- Diagnostics Menu: This menu provides real-time data from the load sensing system, including:
- PLTLOAD: Displays total measured force (empty platform calibration) in kilograms.
- PLTGROS: Displays total measured force (sum of pins 1 thru 4 load) in kilograms.
- OVERLOADED?: Indicates current LSS Module Overload Status (Yes/No).
- CELL 1-4: Displays calibrated cell reading in kilograms and mV/V.
- BATTERY: Displays current battery voltage.
- EXCITE: Displays load pin excitation voltage.
- TEMP: Displays the temperature sensed by the LSS Module for scissor pin compensation.
- SOFTWARE/HARDWARE/ANALYZER: Displays version information for the LSS Module and analyzer.
- Personalities Menu: Allows adjustment of parameters like "OVERLD XXXX LBS" (overload limit), "ACC Y XXXX LBS" (accessory derating), "MTN DELAY XS" (motion delay), "OVR DBNCE XS" (overload debounce delay), and "OVR HOLD XS" (overload hold delay).
- Machine Setup Menu: Used to configure the LSS for a particular JLG model, allowing selection of the machine model (e.g., 4069LE, 3369LE, 500RTS, 260MRT) and units (LBS or KG).
- Calibration Menu: Essential for accurate load sensing. It involves:
- Empty Platform Weight Calibration: Ensures the system accurately measures the empty platform weight.
- Load Calibration: Requires placing a known weight on the platform (e.g., 110% rated load) to calibrate the system.
- Angle Sensor Calibration: Calibrates the angle sensors by lifting the platform to maximum height and lowering it to stowed position.
- Fault Codes: The system provides detailed fault codes (e.g., "PLATFORM OVERLOADED," "BATT TOO LOW," "CELL #1 ERROR," "LSS NOT CALIBRATED") with descriptions of the situation and possible resolutions. These codes are displayed on the analyzer and help in troubleshooting.
- Visual and Audible Overload Warnings: When the platform is overloaded, the system triggers visual and audible warnings, and may prevent further machine movement.
Maintenance Features:
The manual emphasizes the importance of regular maintenance and safety precautions.
- General Safety Precautions: Highlights the need for qualified personnel to perform maintenance, wearing appropriate safety gear, and being aware of potential hazards like heavy objects and moving parts.
- Hydraulic System Safety: Stresses the importance of relieving hydraulic pressure before working on the system.
- Maintenance Procedures:
- LSS Module Installation: Details the process of mounting the LSS module, connecting wiring harnesses, and ensuring proper connections.
- Calibration: Regular calibration of the load sensing system and angle sensors is critical for accurate and safe operation. The manual provides step-by-step instructions for these procedures, including empty platform weight calibration, load calibration, and angle sensor calibration.
- Troubleshooting: Comprehensive troubleshooting charts are provided for various difficulties, including:
- LSS Troubleshooting Chart - General: Addresses issues like the analyzer not displaying, or the LSS module LED not lighting up.
- LSS Troubleshooting Chart - Calibration: Helps resolve problems encountered during calibration, such as "MIN CAL" or "MAX CAL" errors.
- LSS Troubleshooting Chart - Measurement Performance: Guides technicians through issues related to inaccurate load readings or sensor errors.
- LSS Troubleshooting Chart - Host System Functionality: Deals with problems related to the LSS module's communication with the host control system and overload warnings.
- Component Removal/Installation: Provides instructions for replacing key components:
- Pressure Transducer Removal/Installation: Details how to safely remove and install pressure transducers on the lift cylinder.
- Angle Sensor Removal/Installation: Explains how to remove and install angle sensors.
- Wiring Diagrams: Detailed wiring diagrams are included for different models (e.g., 260MRT, M3369/M4069 & 3369LE/4069LE, 500RTS, ES, RT) to assist in diagnosing electrical issues. These diagrams show the connections between the LSS module, load cells, analyzer, and other components.
- Parts Information: The manual includes detailed parts lists and exploded views for the load sensing system installation on various models, with part numbers, descriptions, quantities, and revision information. This helps in identifying and ordering correct replacement parts.
- Revision Log: A revision log tracks updates to the manual, ensuring users have the most current information.
This manual serves as a critical resource for technicians and operators to safely and effectively maintain and troubleshoot JLG Scissors Lift Products equipped with the Load Sensing System.
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