Operation & Safety, Service & Maintenance & Illustrated
Contents
1. 41 2 2 Procedure Overview All Vertical Lifts 2 2 Adjustment Preparation 2 5 2 4 594 eem oy Bn 2 3 Adjustment 2 2 0 0 2 6 rr Rex 2 3 LSS Operation Function 2 4 2 9 COMPONENT 2 2 5 Generali etenim Pea vw Mig 2 5 LSS Panel Component Installation Manually Propelled Lifts 2 5 LSS Indicators Drivable Vertical Lifts 2 6 LSS Platform Mount Attach Arms to Mast Header Installation All 2 6 LSS Limit Switch Installation All 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 vecina epe DIERUM FITUS ME Fes pm e p US 2 8 LCD Display x ise P EARURID RE eae anes CoU PRU CE RUD 2 8 2 6 PLATFORM CONTROL CONSOLE DRIVABLE VERTICAL LIFTS ONLY 2 8 2 7 TROUBLESHOOTING 4 ELE dink ndo aec e N2. Overload Recovery NOTICE Further movement of the platform is permitted by remov THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION ing excess platform load until the LSS resets This may VERIFICATION NOT TO EXCEED 6 MONTHS FROM PREVIOUS require removing load until a load less than rated capacity VERIFICATION is achieved NOTE There is a 5 second delay between overload reset and machine function activation NOTICE THE LOAD SENSING SYSTEM WILL REQUIRE ADJUSTMENT WHEN ONE OR MORE OF THE FOLLOWING CONDITIONS OCCUR e Load Sensing System initial installation LSS component is disassembled or replaced 1 2 JLG Lift 3124289 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM 2 1 LOAD SENSING SYSTEM LSS DESCRIPTION The LSS system for Vertical Mast model machines con sists of a floating platform mount weldment rails attached to the sides of the mast header section transfer D ring the platform load to a load bearing crossmember The platform mount load bearing crossmember is supported n by coil springs mounted between the platform crossmem ber and a crossmember attached to the mast header sec tion 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 port
3. Figure 3 1 PLATFORM SUPPORT amp LOAD SENSING INSTALLATION JLG Lift 3124289 FIGURE 3 1 PLATFORM SUPPORT amp LOAD SENSING INSTALLATION FIG amp ITEM PART NUMBER DESCRIPTION QTY REV LOAD SENSING SYSTEM INSTALLATION CE SPEC Ref 0273264 20AM 25AM Models Ref C 0273265 41 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
4. Aux Output 1 to Light Alarm Harness Plugs 1 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 1 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 1 4922924 4460320 Plug Male 2 Position 1 4460226 Socket Female 2 4360546 Switch Limit 1 3124289 JLG Lift 3 5 3 6 FIGURE 3 1 PLATFORM SUPPORT amp LOAD SENSING INSTALLATION FIG amp ITEM PART NUMBER DESCRIPTION QTY REV JLG Lift 3124289 Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 pla B JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 811111 61 2 65 813058 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 USA 717 485 5161 717 485 6417 JLG Industries
5. UK Ltd Ben Ben tley House tley Avenue Middleton Greater Manchester M24 2GP England EN Di 44 0 161 654 1000 44 0 161 654 1001 3124289 JLG France SAS 2 1 de Baulieu 47400 Fauillet France FF 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Germany 2 49 0 421 69 350 20 d 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 I 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy S 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 FF 65 6591 9030 El 465 6591 9031 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34937724700 34 93 771 1762 JLG Sverige Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 El 46 0 850 659 534 www jlg com
6. 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 24 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 3 4 FIGURE 3 1 PLATFORM SUPPORT amp LOAD SENSING INSTALLATION FIG PART NUMBER DESCRIPTION QTY REV 23 4846859 Load Sensor Weldment 1 24 4846877 Support Spring amp 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 24 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 0 forms 0641626 MP Models 6 41 4711600 Flatwasher 3 8 Narrow MP Models Only 3 0273162 LOAD SENSOR CONTROLLER ASSEMBLY Ref B Note Used on all Machines except DVL DVSP MVL MSP Models 101 0140011 Alarm Warning 1 102 0791408 Sc
7. Connector unused 2 Identification Decal 4 J1 Black Connector used 3124289 JLG Lift 2 7 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM 2 5 GROUND CONTROL MODULE 2 6 PLATFORM CONTROL CONSOLE DRIVABLE VERTICAL LIFTS ONLY The following instructions are supplemental to the DVL DRIVABLE VERTICAL LIFTS ONLY DVSP Operators and Service manuals and show addi tional features on the ground control module for machines equipped with the Load Sensing System Programming E gm m P cap VET The Ground Control Module must be programmed to detect the Load Sensing System before the LSS will func tion 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 188 programming item range as shown following Table 2 3 Ground Control Module Programming Drivable Lifts ONLY PROGRAMMABLE FACTORY ITEM PRESET SETTING RANGE Enable Detection of 2 0 Detection Disabled LSS 1 Enabled Warning Disables Platform Functions Only 2 Enabled Warning Disables Platform and Ground Control Functions LCD Display When an overload warning is detected the following alter nating screens are displayed on the Ground Control Mod ule LCD screen 1 N
8. three 3 second delay between detection and overload indication MANUALLY PROPELLED LIFTS See Figure 1 1 1 Platform Control Panel 3 LSS Warning Alarm 1 The LSS Warning Alarm and Lamp will activate 1 2 L S S Indicator Panel 4 LSS Warning Lamp 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 TUS ORAE H Figure 1 2 Load Sensing System Indicators Drivable Vertical Lifts 60009 Platform Console LED Indicators Drivable Vertical Lifts 1 The platform console LED bar will flash 9 Nine LEDs 1 Ground Control Module 3 LSS Warning Lamp to indicate a Platform Overload condition 2 LSS Warning Decal 4 LSS Warning Alarm 3124289 JLG Lift 1 1 SECTION 1 OPERATION
9. y gt 5 2 PLATFORM OVERLOADED 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 Platform Console LED Indicators 1 The platform console LED bar will flash 9 Nine LEDs to indicate a Platform Overload condition 3124289 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM 2 7 TROUBLESHOOTING The following tables are furnished to provide possible res olutions for common Load Sensing System difficulties The wiring connectors and pins referenced in these trou bleshooting 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 s the LSS platform mounting system secure and undamaged and all mounting arm joints working smoothly Damaged or loose connectors or wires to 188 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 Load 2 Perform adjustment procedures Section 2 2 LSS Setup And Go to Step 3 Done Adjustmen
10. 124289 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM 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 ES M LSS Warning Alarm Installation 1 Alarm Body 2 Alarm Attach Nut LP LSS Warning Lamp Installation 1 Lamp Attach Nut and Washer 2 Lamp Assembly Note Shown with alarm removed for illustrative purposes only q Y A 4 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 Timing Module Installation 1 LSS Indicator Panel 3 LSS Timing Module 2 Module Fasteners 3124289 JLG Lift 2 5 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM LSS Indicators Drivable Vertical Lifts Only LSS Limit Switch Install
11. ER ME BR 2 9 SECTION 3 ILLUSTRATED PARTS TABLECOF CONTENTS nr td be e b SICHERE TIE Der epi 3 1 3124289 JLG Lift TABLE OF CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 L S S Indicator Panel Location Manually Propelled 1 1 1 2 Load Sensing System Indicators Drivable Vertical 1 1 2 1 Load Sensing System Components 1 1 2 1 2 2 Load Sensing System Indicators Drivable Vertical 2 2 2 3 Platform Console LED Indicators Drivable Vertical 2 2 2 4 LSS Component 4 2 2 2 5 LSS Wiring Diagram For Manually Propelled Vertical 2 11 2 6 LSS Wiring Diagram For Drivable Vertical 2 12 3 1 Platform Support amp 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 2 3 2 2 LSS Timing Module J1 Black Connector Pin 2 7 2 3 Ground Control Module Programming Drivable Lifts 2 8 2 4 Troub
12. ITAL RETURN BROWN SHIELD PARE BROWN BLACK SPARE BLACK RED 64 OPTIONAL 0 5 5 0 5 5 DIGITAL RETURN T 0 5 5 SUPPLY 24V DC 15 1 10 4 701 50 4O 60 20 AUX 2 1 1 1 1 z M EN LSS SWITCH EE OPEN OVERLOAD 21 22 2 GROUND STATION MODULE P1 4 800994 9 89999 QQQ 99899809604 949494949 899 Q3H XOV18 3HvdS XDVIB NMONB 35 45 P2 P PLATFORM EM e QQQQQaQea39 LO 0 BLACK 14 TILT SWITCH RETURN INHIBITS LIFT ORIVE B TILT SWITCH BLACK 6 2 3 N AUX 1 OUTPUT 24VDC 5 AMP MAX B 10 9 MA 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 Lift 3 1 3 2
13. TS JLG Lift A INTRODUCTION REVISION LOG 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 B JLG Lift 3124289 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS GENERAL 5g Rub LEV dan ANE A HYDRAULIC SYSTEM SAFETY Eo daa a ds A NETUS REI ER TEM LE TER RR ER EE A P c B SECTION 1 OPERATION 1 1 INTRODUCTION amp 1 1 1 Overload Indication Mate PR ee 1 4 Overload Recovery RR mp RR LR Ue T EE 1 2 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM 2 1 LOAD SENSING SYSTEM LSS 2 1 Manually Propelled Vertical Lift Overload Detection Manually Propelled Lifts 2 1 Drivable Vertical Lift Overload Detection Drivable Vertical 2 1 2 2 LSS SETUP AND
14. 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 ON ET Percent of Maximum Platform Capacity A OVERLOAD 2 MODEL ADJUSTMENT FOSMWE STOP TEST WEIGHT Hs 2205 Coil Spring Pre Load Adjustment Procedure Example As viewed from rear with mast hidden 110 Overload Test Weight Max Platform Capacity 1096 1 Perform the spring pre load adjustment with NO 120 Positive Stop Test Weight Max Platform Capacity 20 LOAD IN THE PLATFORM 2 Adjust the coil spring height item 1 between the Supe Jos duo mast crossmember item 2 and the platform cross 30016 33016 36016 member item 3 to two 2 inches 51mm by loosen 136kg 150kg 163kg ing or tightening the locknut on the bottom of the center bolt item 4 see note below 35016 385 lb 420 b 159kg 175kg 191kg 3 Adjust outside spring bolts items 5 until the locknuts e y on the bottom of the bolts are flush with the end of 500 55016 60016 each bolt The outside bolts will be loose 227kg 250kg 272kg NOTE Machines with capacities up to 300 Ib 136kg only require two coils springs installed on the NOTICE outside bolt po
15. ation All Lifts 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 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 Lifts 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 0625 in 7 Mast Header 4 Attach Arm Assy 8 Platform Mount Assy Note a Apply Loctite 271 to threads on final assembly and torque to 45 ft Ib 61 m 2 6 JLG Lift View From Rear Of Crossmembers View From Rear Mast Header Hidden 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 Ib 136kg only require two coils springs installed on the outside bolt positions Mac
16. d A WARNING 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 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 3124289 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 e 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 SERVICE MANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS e NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVER HEAD SLING 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 SOLVEN
17. dL Operation amp Safety Service amp Maintenance amp Illustrated Parts Manual Supplement JLG LOAD SENSING SYSTEM Vertical Lift Products P N 3124289 July 29 2013 An Oshkosh Corporation Company INTRODUCTION INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS 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 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 A WARNING 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 provide
18. hines with capacities over 300 Ib 136kg require coil springs installed in all three bolt positions 3124289 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM 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 123 BidBoosoosom 1705760A LSS Timing Module Identification Decal with Connector Pin Assignments 1 Module Serial Number 2 Hardware Revision Level 3 Software Revision Level 4 5 J1 Black Pin Assignments used J2 Grey Pin Assignments unused LSS Module Location 1 Timing Module 3 J2 Grey Connector 2 J1 Black Connector 4 LSS Indicator Panel Table 2 2 LSS Timing J1 Black Connector Pin Assignments Pin Signal Description 1 12V Ignition 2 Neg Ground 3 12V Overload Limit Switch Input 4 Spare Input 1 5 Spare Input 2 6 Spare Input 3 7 12 Overload Status Output 8 12V Visual Warning Output 9 12V Audible Warning Output 10 Spare Input 4 11 Spare Input5 12 Spare Input 6 Note Also refer to wiring diagram Figure 2 5 LSS Timing Module 1 Timing Module 3 J2 Grey
19. iew All Vertical Lifts The mechanical portion of the LSS system requires three 3 adjustments to operate properly Plattorm 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 situa tion when the platform is overloaded There is a three 3 second delay between switch opening and warning activation NOTICE 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 FOL LOWING SUB SECTION Figure 2 4 188 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 JLG Lift 3124289 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM Adjustment Preparation Adjustment Procedures 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
20. ion 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 warn ing 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 on the driv able 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 con trol console and GCM LCD screen will flash Platform Overload On the drivable lift the audible warning alarm and flashing war
21. leshooting Machine Indicates Possible False Platform Overload Condition Manually Propelled Vertical 1 2 9 2 5 Troubleshooting Machine Indicates Possible False Platform Overload Condition Drivable Vertical Lifts ple RI eb eee wx ARI 2 9 JLG Lift 3124289 SECTION 1 OPERATION SECTION 1 OPERATION NOTE This manual is intended as a supplement to the indi vidual machine s Operators and Safety Manual Ser LL vice and Maintenance Manual and Illustrated Parts SA Manual in 1 1 INTRODUCTION amp OPERATION IC NOTE It is the responsibility of the owner user operator les sor lessee to read amp understand this manual and the machine Operators amp Safety Manual and to prevent 4 overloading the platform Do not operate a machine with a disconnected or inoperative Load Sensing System 3 The JLG Load Sensing System LSS for Vertical Mast DD Products is designed to detect when actual platform load a exceeds the machine s Maximum Rated Load Capacity 2 When the Maximum Rated Load Capacity is exceeded the following will occur Overload Indication 9 J BI Figure 1 1 L S S Indicator Panel Location Manually Propelled Vertical Lifts NOTE There is a
22. ning lamp are located on the machine s left rear cover See Figure 2 2 Figure 2 1 Load Sensing System Components LSS Timing Module a LSS Indicator Panel a LSS Warning Lamp b LSS Warning Alarm b 1 Platform Mount c 1 Coil Spring Assemblies 7 Crossmember Stops 8 LSS Overload Actuator 9 LSS Limit Switch 0 Mast Header 1 LSS Arm Linkage On initial LSS installation GCM replacement the GCM must be programmed to detect the LSS system in order to function properly See Section 2 5 Ground Control Mod Note a Manually propelled lifts only 3124289 ule in this manual for instructions on GCM LSS detec tion programming b Relocated on arivable lifts See Figure 2 2 c Shown cut away for illustrative purposes only 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 n LIX JH X 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 2 2 LSS SETUP AND ADJUSTMENT Procedure Overv
23. rew 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 20 2 108 3574518 Plate Mounting 1 109 4460908 Connector Female 12 Position 1 LOAD SENSING SYSTEM INSTALLATION CE SPEC Ref 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 Ref D 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 Lift 3124289 FIGURE 3 1 PLATFORM SUPPORT amp LOAD SENSING INSTALLATION FIG PART NUMBER DESCRIPTION QTY REV 4922923 LOAD SENSING HARNESS ASSEMBLY Ref C 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 4922924 LOAD SENSING HARNESS ASSEMBLIES Ref D DVL DVSP MVL MSP MODELS NOT SHOWN 401 Not Available Cable Assembly Light Alarm Harness Plugs into 402 1 Purchase p n 4922924 4460424 Connector Female 2 Position 1 4460267 Pin Male 2 402 Not Available Cable Assembly
24. sitions Machines with capacities WHEN PERFORMING THE FOLLOWING ADJUSTMENTS DO NOT over 300 Ib 136kg require springs installed ADD TO THE WEIGHT IN THE PLATFORM BY ALLOWING ANY im all three boit positions PART OF YOUR BODY TO REST ON THE PLATFORM 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 NOTICE PART OF YOUR BODY TO REST ON THE PLATFORM 1 2 4 Crossmember Positive Stop Adjustment Perform the crossmember positive stop adjustment with 12096 OF MAXIMUM CAPACITY load in the plat form 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 achie
25. t Reload platform to rated capacity is system still indi cating an overload condition 3 Setup and power machine on Check voltage at Timing Module J1 12V Replace Timing Goto Step 4 connector Pin Is voltage up to spec Module 4 Checkcontinuity between Timing Module J1 Pin 3 and Pin 22 on GotoStep5 Repair or Replace the Limit Switch Is there continuity Wiring 5 AttheLimitSwitch check voltage on Pin 21 Is voltage up to spec 12V Replace Limit Goto Step 6 Switch 6 AttheLimitSwitch check Pin 21 connector for loose or damaged Repair or Replace Replace Limit condition Is connector loose or damaged Connector Switch 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 188 components STEP ACTION SPEC YES NO 1 15 platform load at or below the maximum rated platform capacity See Capacity Go to Step 2 Reduce Platform Decal on Machine Load 3124289 JLG Lift 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 Performadjus
26. tment procedures Section 2 2 LSS Setup And Go to Step 3 Done Adjustment Reload platform to rated capacity is system still indi cating an overload condition 3 Check continuity between Ground Control Module P2 connector Replace Ground Goto Step 4 Pins 4 and 13 Is there continuity Control Module 4 Checkcontinuity from Limit Switch Terminal 22 to the Ground Con GotoStep5 Repair or Replace trol Module P2 Connector Pin 4 Is there continuity Wiring 5 Checkcontinuity from Limit Switch Terminal 21 to the Ground Con Readjustor Repair or Replace trol Module P2 connector Pin 13 Is there continuity Replace Limit Wiring Switch 2 10 JLG Lift 3124289 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM n PLATFORM CONTROL BOX 16 5 CABLE PLATFORM EMS BLK WHT BAK OPT I AUX I LLARY LOWER I NG 1 1 1 SWITCH LAMP BLU 1 21 22 L __ LSS MODULE gt gt 2 Figure 2 5 LSS Wiring Diagram For Manually Propelled Vertical Lifts 3124289 JLG Lift 2 11 SECTION 2 SERVICE PROCEDURES LOAD SENSING SYSTEM JUNCTION BOX OUT YELLOW BLACK ES YELLOW 1 SHIELD 1 EM B BLACK RS485B BLUE RS485A ORANGE AUX 1 SIGNAL B RED BLACK AUX 1 RETURN BLUE BLACK 0 5 5 SUPPLY 24V DC RED 0 5 5 DIG
27. ved Tighten both nuts item 4 when proper adjustment is achieved JLG Lift Limit Switch Overload Actuator Adjustment Perform the limit switch overload actuator adjustment with 11096 OF MAXIMUM CAPACITY load in the plat form 2 Setup and power machine on 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 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 Once circuit is open re tighten the actuator lock nut and replace the cover on the limit switch when com plete 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 indica tors NOTE b There is a 5 second RESET delay once the limit switch circuit is closed and before the mod ule resumes normal machine operation LSS Operation Function Check After performing the adjustments outlined previously check the following Machine operates properly when loaded to 10096 rated platform capacity Machine cuts out applicable functions and indicates an overload condition when loaded to 11096 rated platform capacity 3
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