SECTION 5 - JLG CONTROL SYSTEM

SECTION 5. JLG CONTROL SYSTEM

5.1 HAND HELD ANALYZER

men u:
Analyzer Display HELP:PRESS ENTER

Escape Key Enter Key

To return home or Stores and selects Top Level, Sub Level,
access previous menu and item menus

Up & Down Arrow Keys Left & Right Arrow Keys

Used to move between Top Level, Sub
Value Selector
Level, and item menus

Figure 5-1. Hand Held Analyzer

To Connect the Hand Held Analyzer:

1. Connect the four pin end of the cable supplied
with the analyzer, to the diagnostic port (refer
toSection 3.1) and connect 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 backwards.
2. Power up the Control System by turning the lower
key to the platform position and pulling both
emergency stop buttons on.

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 SECTION 5 - JLG CONTROL SYSTEM

Using the Analyzer:

With the machine power on and the analyzer connected If ENTER is pressed again, the display moves to the fol-
properly, the analyzer will display the following: lowing display:

HELP: l og: ( 211)

1:STARTUP ( 2/ 1)
MENU:
HELP:PRESS ENTER

or

(machines with no MDI) (machines with an MDI)

LOGGED HELP
1: STARTUP (2/1): (Or last recorded fault)
HELP:
PRESS ENTER LOG: (211)
1: Power Cycle (Or last recorded fault)
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a At this point, the analyzer will display the highest prior-
displayed menu item, press ENTER. To cancel a selected ity active fault, if any are present. You may scroll through
menu item, press ESC; then you will be able to scroll the fault logs to view what the last fifteen faults were.
using the right and left arrow keys to select a different Use the right and left arrow keys to scroll through the
menu item. fault logs. The active faults, are listed before the first
POWER CYCLE. To return to the top menu, press ESC two
The top level menus are as follows: times.
HELP When a top level menu is selected, a new set of menu
DIAGNOSTICS items may be offered; If for example you choose Person-
ACCESS LEVEL alities:
PERSONALITIES
MACHINE SETUP DRIVE
ACTIVATE TESTS LIFT
CALIBRATION STEER
GROUND
If you press ENTER, at the HELP:PRESS ENTER display,
Pressing ENTER with any of the above displayed menus,
and a fault is present, the analyzer display will scroll the
will display additional sub-menus within the selected
fault across the screen. If more than one fault is present
menu. In some cases the next level is the parameter or
only the highest priority fault will show. The other active
information to be changed. Refer to the flow chart for
faults are viewable in Logged Help. If there was no fault
what menus are available within the top level menus.
detected, the display will read:
You may only view the personality settings for selected
In platform mode, menus while in access level 2. Remember, you may
HELP: (001) always cancel a selected menu item by pressing the ESC
EVERYTHING OK, key.
In ground mode,
HELP: (002)
GROUND MODE OK

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 SECTION 5 - JLG CONTROL SYSTEM

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 con- MENU:
figuration settings which cannot be changed until you ACCESS LEVEL 1
enter a password to advance to a lower level. This
ensures that a setting cannot be accidentally altered. To
change the access level, the correct password must be
entered. To enter the password, scroll to the ACCESS
LEVEL menu. For example:

MENU:
ACCESS LEVEL 2

MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings:

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
password.
Use the UP or DOWN arrow key to enter the second
digit of the password which is 3.
Repeat this process until you have entered all five digits
of the password which is 33271.
Once the correct password is displayed, press ENTER.
The access level should display the following, if the pass-
word was entered correctly:

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 SECTION 5 - JLG CONTROL SYSTEM

Adjusting Parameters Using the Hand Held Machine Setup

Analyzer When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personal-
ity item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU-
LAR MACHINE CAN RESULT IN IMPROPER OPERATION.

PERSONALITIES:
DRIVE ACCEL 0.7s
GROUND ALARM:
1=DESCENT

PERSONALITIES:
DRIVE ACCEL 0.7s
GROUND ALARM:
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if 1=DESCENT
the UP arrow is pressed when at the maximum value The effect of the machine digit value is displayed along
nor will the value decrease if the DOWN arrow is with its value. The above display would be selected if
pressed and the value is at the minimum value for any the machine was equipped with a ground alarm and
particular personality. If the value does not change you wanted it to sound when driving. There are certain
when pressing the up and down arrows, check the settings allowed to install optional features or select the
access level to ensure you are at access level 1. machine model.
When selecting the machine model to match the size of
the machine, the personality settings will return to
default settings.
NOTE: Refer to Table 5-3, Machine Model Adjustment
(Machines with Sevcon - 1600346 Power Module
Only), and Table 5-5, Machine Configuration Pro-
gramming Information (Machines with Sevcon -
1600346 Power Module Only) for the default settings.

Password 33271 will give you access to level 1, which

will permit you to change all machine personality
and/or machine setup settings.

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 SECTION 5 - JLG CONTROL SYSTEM

5.2 TILT SENSOR CALIBRATION

CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PER- Be sure that the machine is parked and stowed on level
FORMANCE OF YOUR MACHINE. ground.
NOTE: Tilt Sensor Calibration can not be performed if the
NOTICE main contactor switch is open due to an alarm.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- Ground Module Software Version 1.5
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASH-
ING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ 1. Enter Access Level 1 and go to the CALIBRATION/
ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOM- TILT SENSOR/LEVEL VEHICLE screen.
MENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI- 2. Choose the right arrow key to view the raw, uncali-
MUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE brated tilt sensor values. If either raw angle reads
COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE ±5.0 or more, the machine is too unlevel and the
SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF software will prohibit calibration. Therefore,
TIME PERIODS TO AVOID HEAVY SATURATION. attempt to dissect the three areas of error to find
the primary contributor:
The flash code is indicated on the face of the platform a. Machine mounting and/or grade:
control box as shown:
Try to measure the top of the Ground Control
box for levelness. If unable to get a good read-
SYSTEM FAULT ing, unbolt the Ground Control box and check
the box’s mounting surface for levelness.
b. Tilt sensor mounting on machine or wedged
crooked in control box:
If the machine mounting/grade appears
acceptable, remove and open the Ground Con-
trol box carefully. Observe whether the tilt sen-
sor is properly seated in its grooves.
c. Tilt sensor has developed an offset shift:
Remove the tilt sensor from the Ground Con-
Diagnostic Trouble Codes are indicated on the MDI for trol box but keep both the tilt sensor and
those machines that are equipped with an MDI. (refer to Ground Control box electrically connected.
Section 3.2). Level one axis of the tilt sensor and observe
the raw reading (should be within ± 2.0). Do
NOTE: Flash codes and DTC’s are also displayed on the
the same for the other axis. If either axis is
handheld analyzer. For descriptions see, Table 5-2,
greater than ±2.0, replace the tilt sensor.
Flash Code Listing.
Ground Module Software Version 1.4
1. Enter Access Level 1 and go to the CALIBRATION/
TILT SENSOR/LEVEL VEHICLE screen.
2. Choose the right arrow key to view the raw, uncali-
brated tilt sensor values. If either raw angle reads
±5.0 or more, the machine is too unlevel and the
software will prohibit calibration. Therefore,
attempt to dissect the three areas of error to find
the primary contributor:
a. Machine mounting and/or grade:
Try to measure the top of the Ground Control
box for levelness. If unable to get a good read-
ing, unbolt the Ground Control box and check
the box’s mounting surface for levelness.
b. Tilt sensor mounting on machine or wedged
crooked in control box:
If the machine mounting/grade appears
acceptable, remove and open the Ground Con-

3121166 – JLG Lift – 5-5

 SECTION 5 - JLG CONTROL SYSTEM

trol box carefully. Observe whether the tilt sen- 5.3 TILT SENSOR ELECTRICAL EVALUATION
sor is properly seated.
c. Tilt sensor has developed an offset shift: This basic check using the JLG Analyzer can be used to
Remove the tilt sensor from the Ground Con- test the Tilt Sensor.
trol box but keep both the tilt sensor and
Ground Control box electrically connected. • If angle measurements read +20.0, then a sensor/
Level one axis of the tilt sensor and observe wiring/connector fault exists. If the readings inter-
the raw reading (should be within ± 2.0). Do mittently display expected angles, then there is likely
the same for the other axis. If either axis is a wiring/connector problem and not a failed sensor.
greater than ± 2.0, replace the tilt sensor. In either case, open the ES Ground box. Disconnect
the sensor, check the wire terminations, and clean
NOTE: Check that the tilt switch is properly set by referring any corrosion on the tilt sensor and control board
to the Tilt Settings table in section 1 of this manual. connections. Reconnect and test. If the fault persists,
replace the tilt sensor and return the faulty tilt sensor
Failure Troubleshooting for The Field to JLG with a detailed description of the diagnostic
steps taken.
Some possible reasons that the tilt sensor will not cali-
brate are:
5.4 ELEVATION ANGLE SENSOR ELECTRICAL
a. The surface the machine is sitting on is off level EVALUATION
by a few degrees (flat doesn’t imply level; park-
ing lots are often not level). These basic checks using the JLG Analyzer can be used
b. The tilt sensor has failed one or both of the to test the Elevation Angle Sensor. If the problem is still
channels (X axis and Y axis). occurring, perform the Tilt vs. Allowed Height Evalua-
tion described below.
c. Tilt sensor has moisture intrusion that has
shifted its output.
• On a level surface, with the Analyzer under DIAG-
d. Water and/or corrosion in the box has cor- NOSTICS/ELEV SENSOR, verify that the elevation
rupted electrical connections or caused a tilt angle sensor voltage increases (ranges from 0.2V-
sensor o r ground control board failure 0.8V to 3.6V-4.2V) with platform height. If not,
(observe any cracks in the box). check the sensor mounting. If necessary, unbolt sen-
e. The Ground Control Box, as mounted on the sor and rotate by hand while monitoring with the
machine, does not allow the tilt sensor to be Analyzer to check the integrity of the sensor output.
level.
• For machines equipped with an elevation proxim-
For the following troubleshooting steps, a bubble level ity switch, if the Elevation Sensor appears satis-
(smaller is better) will be needed and the machine must factory, verify that the Elevation Prox switch is
be on a level surface: opening and closing appropriately by watching
1. On the Analyzer, go to the Diagnostics/System and the change of state between the stowed and ele-
read the tilt angle. If either angle reports +20.0°, vated positions (monitor PROX SWITCH under DIAG-
there is an electrical/electronic failure (tilt sensor, NOSTICS/ELEV SENSOR). If a change of state is not
control board, electrical connections). observed, check prox mounting and operability by
placing metal in front of the prox sensor face.
a. Take the Ground Control box off of the
machine and open the rear cover.
b. Disconnect the sensor and clean any corrosion
off of the tilt sensor and control board connec-
tions.
c. Reassemble and test. If fault persists, replace
tilt sensor.
2. If the Analyzer displays angles other than +20.0°,
attempt to calibrate. If machine won’t calibrate,
note the reason displayed on Analyzer:
a. SENSOR FAILURE – tilt sensor internal fre-
quency is out of range (replace sensor).
b. NOT LEVEL - tilt sensor has either developed an
offset or it is too unlevel as mounted on the
machine.

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 SECTION 5 - JLG CONTROL SYSTEM

Tilt vs. Allowed Height Evaluation Table 5-1. Tilt Settings

First, find a level surface (not just flat like a parking lot; Tilt Setting Tilt Setting Maximum Deck
must be level). The surface should be a plane in which Model
(front to back) (side to side) Elevation
the wheels are within 0°±0.2°. Find this surface by tak-
ing a digital level and measuring the areas on which the 1.5° 18.75 ft (5.7 m)
wheels would rest in both the X and Y directions. Mark 2° 14 ft (4.3 m)
1930ES 3°
the locations and drive the machine to these points. If a 2.5° 11 ft (3.4 m)
level surface can not be found, flat shims or plates may 3° 9 ft (2.7 m)
be place under the wheels to create a level plane for the 1.5° 20 ft (6 m)
wheels. 2° 15 ft (4.5 m)
2030ES 3°
2.5° 12 ft (3.7 m)
In determining the existing tilt angle, read the angle on
3° 10 ft (3 m)
the Analyzer under DIAGNOSTICS/SYSTEM. Do not place
a hand-held level on the machine to determine whether 1.5° 25.4 ft (7.7 m)
the machine is level and lifting to the appropriate 2° 20 ft (6 m)
2630ES 3°
height. Such a measurement will likely be different than 2.5° 16 ft (4.9 m)
the Ground box/tilt sensor angle reading due to manu- 3° 13 ft (4 m)
facturing and mounting tolerances. The tilt angle in 2° 26 ft (7.9 m)
both directions should read within ±0.5° while on a level 2646ES 3° 2.5° 22 ft (6.7 m)
surface. If not, then either the machine has a drifting tilt 3° 20 ft (6 m)
sensor or has been erroneously re-calibrated since the
original factory calibration. 2° 31.75 ft (9.7 m)
3246ES 3° 2.5° 22 ft (6.7 m)
Check the service records to determine whether a re cal- 3° 20 ft (6 m)
ibration has been performed. If so, re-calibrate on the
level surface. If there is no record of an earlier calibra- If the machine does not appear to track the lift cutout
tion, we must assume that the sensor output has drifted. heights and no fault exists as described above, stow the
Therefore, replace the sensor and return to JLG with a machine and re calibrate the Elevation Sensor.
detailed troubleshooting description.
NOTE: There is a rare case in which an attempted calibra-
tion will be unsuccessful for machines with Ground
module software version P1.5 or earlier. If this occurs
while performing a calibration, the Analyzer will dis-
play:
LEVEL VEHICLE
TILT +20.0 +20.0
and the following fault will also be logged.
TILT SENSOR NOT CALIBRATED (2/3) [DTC 811]
If no other faults have been logged since the last
startup, this fault indicates that the software needs to be
updated to P1.6 or later. Update the software and con-
tinue troubleshooting evaluation before replacing any
components.
If the tilt sensor readings are within range for a level
machine, compare the allowed Tilt vs. Height in the
chart below. Being within 6” of the target height is con-
sidered acceptable.

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 SECTION 5 - JLG CONTROL SYSTEM

5.5 ELEVATION SENSOR CALIBRATION 5.6 UPDATING SOFTWARE

Updating the ground module software requires a laptop
NOTICE computer, connecting cable, and software update cd.
MACHINE MUST BE ON LEVEL GROUND BEFORE ELEVATION SEN- Contact JLG Industries to acquire the software cd.
SOR CAN BE SET.
Before updating the software, use the Hand-held Ana-
1. Be sure that the machine is parked and stowed on lyzer to view the machine’s settings (MACHINE SETUP
level ground. and PERSONALITIES) (refer to Figure 5-2. thru Figure 5-4.
for Analyzer Flow Chart). It is important to write down
2. Attach the analyzer near the ground control sta- the settings to verify they are the same after software
tion. update is complete.
3. Go to Access Level 1 and scroll through to CALI-
BRATION. NOTE: Software update must be done with the machine
powered in Ground Mode.
4. Under Calibrations, go to SET ELEV SENSOR.
5. Press enter for Yes and the Elevation Sensor will 1. Disconnect analyzer from diagnostic port.
set. 2. Using the laptop connector cable, connect the lap-
top to the diagnostic port.
NOTE: Check the elevation sensor by lifting the scissor arms,
from the platform, and driving until the drive speed 3. Run the software update cd.
cuts back. Refer to Table 1-13, High Drive Speed Cut- a. When the JLG Reprogramming Tool dialogue
out Height for proper speed cut out height. box appears, click on the Program button.
b. Another dialogue box will appear asking if you
want to overwrite the current software version.
Click YES.
4. After software update is complete, disconnect
computer from diagnostic port.
5. Reconnect the hand-held analyzer to the diagnos-
tic port.
a. Enter Access Level 1 password; 33271
b. Scroll to MACHINE SETUP. Change MODEL
NUMBER to a different model, but immediately
change it back to the proper setting. Do the
same for MARKET. This will ensure the settings
are carried over to all parameters.
c. Scroll through the settings to verify they are
the same as before the software update.
6. Disconnect Analyzer.
7. Software update is complete.

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 SECTION 5 - JLG CONTROL SYSTEM

5.7 TROUBLESHOOTING
It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.
It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and
electrical systems.
The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if
the circuit is lacking hydraulic oil and electrical control power. This can be ascertained by overriding the bypass valve
(mechanically or electrically) so that oil is available to the function valve, then overriding the function valve mechani-
cally. If the function performs satisfactorily, the problem exists with the control circuit.
NOTE: It may also be helpful to do the following for intermittent or difficult problems: run a system test, ANALYZER -> SYSTEM
TEST; check the machine personalities, ANALYZER ->PERSONALITIES (refer to Table 5-3, Machine Model Adjustment
(Machines with Sevcon - 1600346 Power Module Only)); and check the machine setup, ANALYZER -> MACHINE SETUP
(refer to Table 5-5, Machine Configuration Programming Information (Machines with Sevcon - 1600346 Power Module
Only)).

These below flash codes apply only to machines without the MDI (refer to Section 3.2, MDI (Multifunction Digital Indica-
tor) and brake release). For machines with the MDI, refer to Section 6, Diagnostic Trouble Codes.

Anytime a problem is resolved, recycle the EMS.

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code

Help Messages with no flash code may occur during normal operation and explain various vehicle interlocks.
Platform is elevated and the chassis is not level.
Platform Position Sensor (PPS) elevation status is elevated and
0 0 ALARM SOUNDING--TILTED AND ABOVE ELEVATION
the vehicle is tilted and machine setup’s TILT CUTOUT is 0=YES.
No motion restrictions.
Platform is elevated and the machine is in the drive mode of
operation.
In platform mode, Platform Position Sensor (PPS) elevation
0 0 DRIVING AT CUTBACK -- ABOVE ELEVATION
status is elevated and the vehicle is driving and the drive speed
is drive elevated.
Driving at elevated speed.
Driving is not possible since the platform is elevated and the
chassis is not level.
In Platform Mode, Platform Position Sensor (PPS) elevation
0 0 DRIVE & LIFT UP PREVENTED -- TILTED & ELEVATED
status is elevated and the vehicle is tilted and machine setup’s
TILT CUTOUT is 1=YES.
Drive prevented.

Applicable to 3246ES configured for the Zone A/B Capacity

Selection, and operating on Zone A. The vehicle has reached
the maximum height and further lift up motion is not possible.
0 0 LIFT UP PREVENTED -- MAX HEIGHT ZONE A
Machine Setup’s CAPACITY SELECT is 1=ZONE A/B and Machine
Setup’s MODEL is 3246ES and Zone A Lift Up=False.
Lift up prevented.

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 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
While stowed, drive speed is reduced (due to lower ground
clearance) since the control system detected that the pot-hole
Clear the obstacle blocking the
protection mechanism is deployed (failed to retraced).
pot-hole protection mecha-
In platform mode with a healthy elevation sensor, elevation
nism, repair the mechanical
0 0 DRIVING AT CUTBACK -- POTHOLE STILL ENGAGED sensor less than 0.15V and the elevation prox closed and pot-
problem, re-adjust the pot-hole
hole protection’s PHP switches detect down.
limit switches, or repair the wir-
In platform mode with an unhealthy elevation sensor, the ele-
ing to correct the problem.
vation prox is closed AND pot-hole protection’s PHP switches
detect down.
Check batteries charge, condi-
After 2 hours without activity, the control system enters a low- tion, etc. Normal operation
0 0 FUNCTIONS LOCKED OUT -- SYSTEM POWERD DOWN
power state to preserve battery charge. should resume after a power
cycle.
The Drive Cutout functionality is enabled, and the platform is
elevated above the calibrated cutout height.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
DRIVE PREVENTED -- ELEVATED AND ABOVE DRIVE CUT- Check elevation switches
0 0 “Healthy” AND the Elevation Sensor’s Zeroed Voltage is Greater
OUT HEIGHT Check pothole switches.
Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.

Help messages with the 2-1 flash code occur during after power-up of the vehicle control system.
This help message is issued at each power-up. This serves to
indicate which messages have been recorded in logged help
2 1 STARTUP since the last power-up event.
No motion restrictions.
No motions restricted.
The platform and ground mode inputs from the keyswitch are
active at the same time. The control system will default to
ground mode when if this happens. The keyswitch and wiring Re-cycle power once the prob-
KEYSWITCH FAULTY -- PLATFORM & GROUND ACTIVE
2 1 inside the ground control box should be examined / repaired. lem has been resolved to clear
TOGETHER
Platform EMS digital input energized and ground mode select this difficulty.
digital input energized.
Default to ground mode operation and lift up prevented
Help messages with the 2-2 flash code indicate difficulty with the platforms controls.
Horn switch in the platform control box was closed during
power-up.
In platform mode, the Indoor/Outdoor switch digital input is Release or repair the switch to
2 2 FUNCTION PROBLEM -- HORN PERMANENTLY SELECTED
energized and power-up is active. Retained until either is clear the message.
momentarily de-energized.
Previously selected Indoor/Outdoor mode maintained.

Indoor / Outdoor switch in the platform control box was closed

during power-up.
FUNCTION PROBLEM -- INDOOR / OUTDOOR PERMA- In Platform Mode, the Indoor / Outdoor Switch Digital Input is Release or repair the switch to
2 2
NENTLY SELECTED Energized and Power-up is Active. Retained until Digital Input clear the message.
is momentarily De-energized.
Previously selected Indoor / Outdoor Mode maintained

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 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Drive - Lift selector switch indicates that both functions are
selected simultaneously.
In Platform Mode, the Drive and Lift Digital Inputs are Ener- Repair the wiring or switch to
2 2 FUNCTION PROBLEM -- DRIVE & LIFT ACTIVE TOGETHER
gized at the same time. Retained until either is momentarily clear the message.
De-energized.
Drive, Steer, & Lift Prevented
Steer left switch in the platform control box was closed during
power-up.
FUNCTION PROBLEM -- STEER LEFT PERMANENTLY In Platform Mode, the Left Steer Digital Input Switch is Ener- Release or repair the switch to
2 2
SELECTED gized AND Power-up is Active. Retained until Digital Input is clear the message.
momentarily De-energized.
Steer & Drive Prevented
Steer right switch in the platform control box was closed dur-
ing power-up.
FUNCTION PROBLEM – STEER RIGHT PERMANENTLY In Platform Mode, the Right Steer Digital Input Switch is Ener- Release or repair the switch to
2 2
SELECTED gized and Power-up is Active. Retained until Digital Input is clear the message.
momentarily De-energized.
Steer & Drive Prevented.
The joystick (accelerator) wiper signal input is outside the
The wiper wire being off, the
acceptable voltage range.
wiper wire shorted to +B, or the
In Platform Mode, the Joystick (accelerator) Analog Input
2 2 ACCELERATOR FAULTY – WIPER OUT OF RANGE wiper wire shorted to –B
Switch is > 4.50V OR < 0.50V. Retained until Analog Input is
(ground) could cause this diffi-
measured within proper range.
culty.
Drive, Steer, & Lift Prevented.
Both the steer left and steer right inputs are closed as the same
time.
A short in the steer switch wir-
ACCELERATOR FAULTY – STEER SWITCHES ACTIVE In Platform Mode, the Steer Left Digital Input is Energized and
2 2 ing or a failed steer switch can
TOGETHER the Steer Right Digital Input is Energized. Retained until either
cause this difficulty.
Digital Input is momentarily De-energized.
Drive & Steer Prevented.
Selected function (drive or lift) is not allowed because the joy-
stick (accelerator) was not centered at power-up.
In Platform Mode, scaled Joystick (accelerator) position was Return joystick to center
2 2 FUNCTION LOCKED OUT – ACCELERATOR NOT CENTERED
something other than 0% AND Power-up was Active. Retained momentarily and re-initiate.
until the Joystick is momentarily centered.
Drive, Steer, & Lift Prevented.
Trigger switch in the platform control box was closed at power-
up.
Release switch or repair the
FUNCTION PROBLEM – TRIGGER PERMANENTLY CLOSED In Platform Mode, the Trigger Digital Input was Energized AND
2 2 switch / wiring to clear the diffi-
Power-up was Active. Retained until the Trigger Digital Input is
culty.
momentarily De-energized.
Drive, Steer, & Lift Prevented.
Trigger switch in the platform control box was closed for more
than ten seconds while the joystick (accelerator) was in the
neutral position (centered).
In Platform Mode, the Trigger Digital Input was Energized for Release switch or repair the
2 2 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL 10,000mS AND Drive was In-Active AND Lift was In-Active. switch / wiring to clear the diffi-
Retained until the Trigger Digital Input is momentarily De- culty.
energized.
Drive, Steer, & Lift Prevented.

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 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Help messages with the 2-3 flash code indicate difficulty with the ground controls.
Lift switch (up or down) in the ground control box was closed
during power-up.
In Ground Mode, [Lift Up Digital Input is Energized or Lift Down
FUNCTION PROBLEM – LIFT PERMANENTLY SELECTED Release or repair the switch to
2 3 Digital Input is Energized] AND Power-up is Active. Retained
clear the message.
until the respective Digital Input is momentarily De-ener-
gized.
Lift Prevented
In ground mode, the control system has detected the lift up
and down are active simultaneously.
Check the lift switch and associ-
In Ground Mode, Ground Lift Up Digital Input is Energized and
2 3 GROUND LIFT UP/DOWN ACTIVE TOGETHER ated wiring in the ground con-
Ground Lift Down Digital Input is Energized. Retained until
trol box.
both the Digital Inputs are momentarily De-energized.
Lift Prevented
No signal from the tilt sensor mounted inside the ground con-
trol box.
Transitions on the Tilt X OR Tilt Y signals not detected for
Check wiring and plug connec-
NO DATA FROM TILT SENSOR – NOT CONNECTED OR 2000mS. Retained until transitions on both are sensed.
2 3 tions at the tilt sensor and at the
FAULTY Vehicle assumed Tilted (+20.0’ X, +20.0’ Y); Drive Stowed
ground control board.
Demand limited as in Worst-Case Slope Descent Functionality
for both Forward and Reverse
Drive will be slow in the Forward direction.
The Tilt Sensor’s Calibration EEPROM is set to the signature
implanted by the In-Circuit Test Fixture. Retained until Calibra-
tion EEPROM is over-written by a valid calibration. Calibrate the Tilt Sensor using
2 3 TILT SENSOR NOT CALIBRATED Vehicle assumed Tilted (+20.0’ X, +20.0’ Y); Drive Stowed the calibration procedure to
Demand limited as in Worst-Case Slope Descent Functionality clear the message.
for both Forward and Reverse
Drive will be slow in the forward direction.
Check if the lift switch is
obstructed or jammed. Check
FUNCTION PROBLEM -- BRAKE RELEASE PERMANENTLY The ground control box lift switch was closed up or down, dur-
2 3 the lift switch signal and wiring
SELECTED ing power-up in ground mode.
to the ground board. Replace
ground board.
Help messages with the 2-5 flash code indicate that a function is prevented due to a cutout.

The input voltage from the sensor that measures lower arm
motion is outside acceptable range. This may be caused by Check mounting, review sensor
ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR VOLT- improper sensor mounting, difficulty with the sensor wiring, wiring against the electrical
2 5
AGE OUT OR RANGE or a faulty sensor. schematic, or replace the sensor
The elevation sensor is unhealthy to clear the message.
Platform height assumed to be full elevation.

5-12 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Elevation Sensor’s Calibration EEPROM is set to the signa-
ture implanted by the In-Circuit Test Fixture. Retained until
Calibration EEPROM is over-written by a valid calibration.
Platform Height assumed to be Full Elevation.
The Elevation Proximity Switch is Open to indicate that the Calibrate the elevation angle
2 5 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Platform is Elevated, but the Elevation Sensor’s Voltage indi- sensor using the calibration pro-
cates that the Platform is Stowed. To be conservative, the con- cedure to clear the message.
trol system will assume that the Platform is Elevated.
Elevation Sensor is “Healthy” AND the Elevation Sensor’s
Zeroed Voltage is < 0.04V AND the Elevation Prox Switch is
Open for 2000mS. Retained until situation changes.
Driving is not possible since the vehicle is charging and it is con-
figured to only allow lifting.
In Platform Mode, the Battery Charger is Charging AND the
2 5 DRIVE PREVENTED – CHARGER CONNECTED Disconnect battery charger
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 0=DRIVE ONLY.
Drive & Steer Prevented
Driving and lifting are not possible since the vehicle is charging
and it is configured to prevent all motion.
In Platform Mode, the Battery Charger is Charging AND the
2 5 DRIVE & LIFT UP PREVENTED – CHARGER CONNECTED Disconnect battery charger
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 1=DRV & LIFT UP.
Drive & Lift Up Prevented.
While the Load Sensing System is enabled, the platform load
measured by the Load Sensing System is excessive. Functions
from platform control are prevented, and functions from
ground control may be prevented, depending on machine con-
Remove excess weight from
figuration.
2 5 PLATFORM OVERLOADED platform.
The Load Sensing System Functionality’s Overload is True AND
[Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL].
Drive, Steer, & Lift Prevented (except 3246ES CE, Indoor Mode,
Height >24 Ft and < 26Ft, Lift Dn allowed).

While elevated, driving is not possible since the control system

detected that the pot-hole protection mechanism failed to
deploy.
Clear the obstacle blocking the
In Platform Mode with a Healthy Elevation Sensor, the Eleva-
pot-hole protection mecha-
tion Sensor Voltage > 0.15V AND Pot-Hole Protection’s PHP
nism, repair the mechanical
2 5 DRIVE PREVENTED – POTHOLE NOT ENGAGED Switches detect Up.
problem, re-adjust the pot-hole
In Platform Mode with an Unhealthy Elevation Sensor, the Ele-
limit switches, or repair the wir-
vation Prox Sensor is Open (no Arm Detected) AND Pot-Hole
ing to correct the problem.
Protection’s PHP Switches detect Up.
Drive & Steer Prevented.

3121166 – JLG Lift – 5-13

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Elevation Proximity Switch is closed to indicate that the
platform is stowed, but the elevation sensor’s voltage indicates
that the platform is elevated. To be conservative, the control
ELEV PROX PERMANENTLY CLOSED – CHECK PROX AND system will assume that the platform is elevated, and the drive
Check elevation switches.
2 5 ANGLE ADJUSTMENT speed will be restricted to elevated.
Replace if necessary.
Elevation Sensor is “Healthy” AND the Elevation Sensor’s
Zeroed Voltage is > 0.15V AND the Elevation Prox Switch is
Closed for 2000mS. Retained until situation changes.
Refer to Platform Position Sensor Functionality.
The manual brake release has been activated to allow the vehi-
DRIVE & LIFT PREVENTED – BRAKES ELECTRICALLY
cle to be towed. Disengage the manual brake
2 5 RELEASED FOR TOWING
Brake release digital input is energized release.
Drive and Lift Prevented
The Drive Cutout functionality is enabled, and the platform is
elevated above the calibrated cutout height.
DRIVE PREVENTED – ELEVATED ABOVE DRIVE CUTOUT Drive Cutout is set to 1=YES AND the Elevation Sensor is Check elevation switches
2 5
HEIGHT “Healthy” AND the Elevation Sensor’s Zeroed Voltage is Greater Check pothole switches.
Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.
Check ANALYZER -> MACHINE
MODEL CHANGED -- HYDRAULICS SUSPENDED - CYCLE
2 5 The model selection has been changed. SETUP -> MODEL NUMBER.
EMS
Replace ground board.
Ensure vehicle is not stuck on
something preventing move-
While driving on a level surface, armature current was > 150A
2 5 DRIVE PREVENTED -- BRAKES NOT RELEASING ment. Check/repair drive motor
for five seconds. Brakes assumed to not be releasing properly.
wiring, brakes or mechanical
issues.
Help messages with the 3-1 flash code indicate that a contactor did not close when energized.
The Power Module’s line contactor drive circuitry passed
power-up self-tests, but the line contactor did not close when
Refer to CANbus documentation
energized.
3 1 OPEN CIRCUIT LINE CONTACTOR for Power Module Message -
The Power Module is reporting a “Contactor Did Not Close”
Status.
Fault Code (15d).
Drive, Steer, & Lift Up Prevented.
The Power Module’s Line Contactor drive circuitry failed to
energize during power-up self-tests. Refer to CANbus documentation
3 1 CONTACTOR DRIVER PERMANENTLY OFF The Power Module is reporting a “Contactor Driver 1 Perma- for Power Module Message -
nently Off” Fault Code (22d). Status.
Drive, Steer, & Lift Up Prevented.
Help messages with the 3-2 flash code indicate that a contactor did not open when de-energized.

The Power Module’s Line Contactor Drive Circuitry passed

power-up self-tests, but the line contactor did not open when
Refer to CANbus documentation
de-energized.
3 2 LINE CONTACTOR MISWIRED ON OR WELDED for Power Module Message -
The Power Module is reporting a “Contactor Welded” Fault
Status.
Code (14d).
Drive, Steer, & Lift Up Prevented.

5-14 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Power Module’s Line Contactor Drive Circuitry failed to de-
energize during power-up self-tests.
Refer to CANbus documentation
The Power Module is reporting a “Contactor Driver 1 Perma-
3 2 CONTACTOR DRIVER PERMANENTLY ON for Power Module Message -
nently On” Fault Code (23d). Refer to CANbus documentation
Status.
for Power Module Message – Status.
Drive, Steer, & Lift Up Prevented.
Help messages with the 3-3 flash code indicate an output driver problem.
NOTE: Certain output driver problems cannot be detected because stimulation of the load could result in safety con-
cerns or annoyance (brake open circuit, lift down open circuit, ground alarm open circuit). 3-3 help messages
shall be latched until the next power cycle.
Voltage was detected on the brake solenoid when the output
driver was commanded off during power-up.
BRAKE SHORT TO BATTERY
3 3 Brake INPUT driven Low AND Brake STAT detected Low during
power-up.
Drive, Steer, & Lift Prevented.
Current flow to the brake solenoid was not detected during
normal brake operation.
3 3 BRAKE OPEN CIRCUIT Brake INPUT driven High (normal operation) AND Brake STAT
detected Low.
Drive & Steer Prevented
Voltage was detected on the lift up solenoid when the output
driver was commanded off during power-up.
3 3 LIFT UP SHORT TO BATTERY Lift Up INPUT driven Low AND Lift Up STAT detected Low during
power-up.
Drive, Steer, & Lift Up Prevented.
Current flow to the lift up solenoid was not detected during
power-up.
3 3 LIFT UP OPEN CIRCUIT Lift Up INPUT driven High (momentarily) AND Lift Up STAT
detected Low during power-up.
No motion interlocks.
Voltage was detected on the lift down solenoid when the out-
put driver was commanded off during power-up.
3 3 LIFT DN SHORT TO BATTERY Lift Down INPUT driven Low AND Lift Down STAT detected Low
during power-up.
No motion interlocks.
Current flow to the lift down solenoid was not detected during
normal lift down motion.
3 3 LIFT DN OPEN CIRCUIT Lift Down INPUT driven High (normal operation) AND Lift
Down STAT detected Low.
Lift Up Prevented.

Voltage was detected on the steer left solenoid when the out-
put driver was commanded off during power-up.
Left Turn INPUT driven Low AND Left Turn STAT detected Low
3 3 STEER LEFT SHORT TO BATTERY
during power-up.
Drive & Steer Prevented.

3121166 – JLG Lift – 5-15

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Current flow to the steer left solenoid was not detected during
power-up.
3 3 STEER LEFT OPEN CIRCUIT Left Turn INPUT driven High (momentarily) AND Left Turn STAT
detected Low during power-up.
Drive & Steer Prevented.
Voltage was detected on the steer right solenoid when the out-
put driver was commanded off during power-up.
3 3 STEER RIGHT SHORT TO BATTERY Right Turn INPUT driven Low AND Right Turn STAT detected
Low during power-up.
Drive & Steer Prevented.
Current flow to the steer right solenoid was not detected dur-
ing power-up.
3 3 STEER RIGHT OPEN CIRCUIT Right Turn INPUT driven High (momentarily) AND Right Turn
STAT detected Low during power-up.
Drive & Steer Prevented.
While the load sensing system was enabled, voltage was
detected on the ground control box’s overload lamp when the
output driver was commanded off during power-up.
3 3 GROUND OVERLOAD LAMP SHORT TO BATTERY Ground Overload INPUT driven Low AND Ground Overload STAT
detected Low during power-up AND [Machine Setup’s LOAD
set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
No motion interlocks.
While the Load Sensing System was enabled, current flow to
the ground control box’s overload lamp was not detected dur-
ing power-up.
Ground Overload INPUT driven High (momentarily) AND
3 3 GROUND OVERLOAD LAMP OPEN CIRCUIT
Ground Overload STAT detected Low during power-up AND
[Machine Setup’s LOAD set to 1=CUTOUT PLT OR 2=CUTOUT
ALL].
No motion interlocks.
While enabled, voltage was detected on the ground alarm
when the output driver was commanded off during power-up.
GROUND ALARM SHORT TO BATTERY Ground Alarm INPUT driven Low AND Ground Alarm STAT
3 3
detected Low during power-up AND [Machine Setup’s
GROUND ALARM set to 1=DECENT OR 2=MOTION].
No motion interlocks.
Check for continuity through
The ground board detected voltage while the left brake was this circuit. Inspect the wiring
3 3 LEFT BRAKE SHORT TO BATTERY
commanded off. for physical damage.
Replace ground board.
Check for continuity through
Current flow to the left brake solenoid was not detected during this circuit. Inspect the wiring
3 3 LEFT BRAKE OPEN CIRCUIT
normal left brake operation. for physical damage.
Replace ground board.

Check for continuity through

Voltage was detected on the right brake solenoid when the this circuit. Inspect the wiring
3 3 RIGHT BRAKE SHORT TO BATTERY
ground board output was commanded off during power-up. for physical damage.
Replace ground board.

5-16 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Check for continuity through
The ground board did not detect current flow to the right brake this circuit. Inspect the wiring
3 3 RIGHT BRAKE OPEN CIRCUIT
during normal operation. for physical damage.
Replace ground board.
Help messages with the 4-2 flash code indicate a thermal problem.
The Power Module for drive, steer, and lift up has reached ther-
POWER MODULE TOO HOT – PLEASE WAIT
4 2 mal cutout. Allow to cool by powering down.
The power Module is reporting a "Unit Too Hot" fault code.
The drive portion of the Power Module has reached thermal
DRIVING AT CUTBACK -- POWER MODULE CURRENT limit. Allow to cool by waiting for temperature to fall.
4 2 LIMIT
The Power Module is reporting a "I2T Drive Current LImit" fault
code.
The lift up portion of the power module has reached thermal
LIFT UP AT CUTBACK -- POWER MODULE CURRENT LIMIT limit. Allow to cool by waiting for temperature to fall.
4 2
The POwer Module is reporting "I2Pump Current LImit" fault
code.
Help messages with the 4-4 flash code indicate a battery supply problem.
Battery Voltage momentarily dropped below 14.5V. With a
low battery charge, this can occur during heavy current
BATTERY VOLTAGE TOO LOW – SYSTEM SHUTDOWN demand due to drive, steer, or lift up. Recharge batteries or check for
4 4
The Power Module is reporting a “Low Battery” Fault Code damaged batteries.
(7d).
Drive, Steer, & Lift Up Prevented
The Power Module momentarily measured excessively high
battery voltage (>37.0v) and the ground module de-ener-
gized the ignition relay to protect system devices.
The Power Module is reporting a “High Battery” Fault Code (8d) This may be due to improper
BATTERY VOLTAGE TOO HIGH – SYSTEM SHUTDOWN
4 4 OR a “High Battery without Line” Fault Code (10d). In response, battery charging or incorrect
the Ground Module shall de-energize the Ignition Relay and voltage batteries being used.
suppress all Help Messages caused by the lack of Ignition Sig-
nal. This fault is latched until the next power-cycle.
Drive, Steer, & Lift Prevented.
While the Load Sensing System is enabled, the Load Sensing
System module measured battery voltage >34.0Vdc, which
may compromise ability to predict weight. This may be due to improper
LSS BATTERY VOLTAGE TOO HIGH
4 4 LSS Module Message – Status Message (0x81) is reporting battery charging or incorrect
“BATT TOO HIGH” AND [Machine Setup’s LOAD is set to 1=CUT- voltage batteries being used.
OUT PLT OR 2=CUTOUT ALL]. Vehicle assumed to be Over-
loaded.
While the Load Sensing System is enabled, the Load Sensing
System module measured battery voltage <9.0vdc, which
may compromise ability to predict weight. With a low battery
charge, this can occur during heavy current demand due to
LSS BATTERY VOLTAGE TOO LOW drive, steer, or lift up. Recharge batteries or check for
4 4
LSS Module Message – Status Message (0x81) is reporting damaged batteries.
“BATT TOO LOW” AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.

3121166 – JLG Lift – 5-17

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Help messages with the 6-6 flash code indicate vehicle communication (CANbus) problems. These faults shall not be latched. Normal operation shall
resume if difficulty is resolved.
The control system failed to receive messages from the Power
Module.
Check wiring at the ground con-
CANBUS FAILURE: POWER MODULE Power Module Message – Status (0x24) not received for
6 6 trol box and power module.
1000mS or Power Module is reported a “CANbus Bus Difficulty”
Recycle power to clear difficulty.
Fault Code (0x09).
Drive, Steer, & Lift Up Prevented.
In Platform Mode, the control system failed to receive mes-
sages from the platform module.
Check wiring at the platform
Digital Input Message – Motion (0x00) not received for
CANBUS FAILURE: PLATFORM MODULE and ground control boxes. Check
6 6 1000mS AND Platform Mode selected. Retained until power is
wiring along scissor arms lead-
re-cycled.
ing up to Platform.
All Platform functions Prevented. Normal operation from
Ground Mode.
With the Load Sensing System enabled, the control system
failed to receive messages from the Load Sensing System Mod-
Check wiring at the Load Sens-
ule.
CANBUS FAILURE: LOAD SENSING SYSTEM MODULE ing System Module and along
6 6 LSS Module Message – Load Cell Message (0x80) not received
scissor arms leading up to plat-
for 1000mS AND [Machine Setup’s LOAD set to 1=CUTOUT PLT
form.
OR 2=CUTOUT ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded.
A JLG Accessory Module has failed to maintain CANbus com-
munications with the ground module.
ACCESSORY CAN COMMUNICATION LOST The control system received Accessory Message – Control 1 Refer to documentation for the
6 6
from an Accessory Module, but failed to receive another within JLG Accessory to clear difficulty.
1000mS. Retained until power is re-cycled.
No motion interlocks.
Help messages with the 6-7 flash code indicate JLG accessory problems. These faults shall not be latched. Normal operation shall resume if difficulty
is resolved.
A JLG Accessory Module has encountered a fault condition and
reported it via the host control system.
Refer to documentation for the
6 7 ACCESSORY FAULT Accessory Message – Control 1’s Request Accessory Fault flag is
JLG Accessory to clear difficulty.
set to YES. Retained or cleared based on status of flag.
No motion interlocks.
Help messages with the 7-7 flash code indicate motor problems.
The Power Module detected an error in the power wiring (F1 &
F2 Terminals) for the drive motors.
OPEN-CIRCUIT DRIVE MOTOR FIELD WIRING Check power wiring and re-
7 7 The Power Module is reporting a “Field Open Circuit” Fault
cycle power to clear difficulty.
Code (16d). Retained until power is re-cycled.
Drive & Steer Prevented
Help messages with the 8-x flash codes indicate problems with the platform load sensing system. The second digit of the flash code is used to indi-
cated channel.
Cell #1’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #1’s Internal Memory.
8-1 Flash Code This situation indicates that the
LSS CELL #1 ERROR
8 1 LSS Module Message – Status Message (0x81) is reporting sensor is unplugged, or the sen-
“CELL 1 ERROR” AND [Machine Setup’s LOAD is set to 1=CUT- sor is damaged.
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.

5-18 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Cell #2’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #2’s Internal Memory.
This situation indicates that the
8-2 Flash Code
LSS CELL #2 ERROR sensor is unplugged, or the sen-
8 2 LSS Module Message – Status Message (0x81) is reporting
sor is damaged.
“CELL 2 ERROR” AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
Cell #3’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #3’s Internal Memory.
8-3 Flash Code This situation indicates that the
LSS CELL #3 ERROR
8 3 LSS Module Message – Status Message (0x81) is reporting sensor is unplugged, or the sen-
“CELL 3 ERROR” AND [Machine Setup’s LOAD is set to 1=CUT- sor is damaged.
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
Cell #4’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #4’s Internal Memory.
8-4 Flash Code This situation indicates that the
LSS CELL #4 ERROR
8 4 LSS Module Message – Status Message (0x81) is reporting sensor is unplugged, or the sen-
“CELL 4 ERROR” AND [Machine Setup’s LOAD is set to 1=CUT- sor is damaged.
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
Help messages with the 9-x flash codes indicate controller (module) problems. The second digit of the flash code provides additional information
about the difficulty.
The Watchdog Timer on Load Sensing System Module’s micro-
processor was triggered by exposure to excessive electrical
noise, or by a hardware difficulty.
9-1 Flash Code
LSS WATCHDOG RESET Re-cycle power to clear diffi-
9 1 LSS Module Message – Status Message (0x81) is reporting
culty
“WATCHDOG RST” AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL]. Retained until power is re-
cycled.
No motion interlocks.
Memory used to retain settings on Load Sensing System Mod-
ule has been corrupted and must be reset by verifying all
entries / re-calibrating.
LSS EEPROM ERROR
9-2 Flash Code After resolution, re-cycle power
9 2
LSS Module Message – Status Message (0x81) is reporting to clear difficulty.
“EEPROM ERROR” AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded

9-3 Flash Code

The Load Sensing System’s Calibration EEPROM for Empty Plat-
form Load is set to Never Set (signature implanted by the In- Calibrate the Load Sensing Sys-
LSS HAS NOT BEEN CALIBRATED
9 3 Circuit Test Fixture) AND [Machine Setup’s LOAD is set to tem using the calibration proce-
1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained until Calibration dure to clear the message.
EEPROM is over-written by a valid calibration.
Vehicle assumed to be Overloaded.

3121166 – JLG Lift – 5-19

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Excitation Voltage for the Load Sensors < 4.25V.
9-9 Flash Code The sensors may be excessively
LSS Module Message – Status Message (0x81) is reporting loading the Excitation Supply
LSS INTERNAL ERROR – PIN EXCITATION
9 9 “INTERNAL ERROR – PIN EXCITATION < 4.25V” AND [Machine due to wiring damage, or the
Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Load Sensing System Module
Retained until power is re-cycled. may have hardware difficulty.
Vehicle assumed to be Overloaded.
The DRDY Interrupt from the Load Sensing System Module’s A/
D Converter is missing.
9-9 Flash Code
This may indicate Load Sensing
LSS INTERNAL ERROR – DRDY MISSING FROM A/D LSS Module Message – Status Message (0x81) is reporting
9 9 System Module hardware diffi-
“INTERNAL ERROR – DRDY INTERRUPT FROM A/D” AND
culty.
[Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded.
The Power Module detected an out-of-range or corrupt per-
sonality setting.
9-9 Flash Code Reset control system Personali-
POWER MODULE FAILURE: PERSONALITY RANGE ERROR
9 9 The Power Module is reporting a “Configuration Range” Fault ties to default settings to clear
Code (11d) OR a “Configuration CRC” Fault Code (12d) OR a difficulty.
“Motor Setup” Fault Code (13d). Retained until power is re-
cycled.
The Power Module detected an internal error via self-test.
9-9 Flash Code
The Power Module is reporting a “Two Direction” Fault Code
POWER MODULE FAILURE: INTERNAL ERROR Re-cycle power to clear diffi-
9 9 (4d) OR a “Sequence” Fault Code (5d) OR a “CANbus Input”
culty.
Fault Code (6d) OR a “12V Supply Detection” Fault Code (18d)
OR a “System Monitor Activated” Fault Code (24d). Retained
until power is re-cycled.
The Power Module detected an error in the Power Wiring for
the Drive or Pump. Alternately, the Power Module has failed a
self-test.
POWER MODULE FAILURE: CHECK POWER CIRCUITS OR 9-9 Flash Code Check wiring and motors or
9 9 MOSFET SHORT CIRCUIT The Power Module is reporting an “Armature MOSFET Short replace the Power Module. Re-
Circuit” Fault Code (17d) OR an “Armature MOSFET’s Off” Fault cycle power to clear difficulty.
Code (19d) OR an “Armature MOSFET’s On” Fault Code (20d) OR
an “Armature Pullup MOSFET Short Circuit” Fault Code (21d).
Retained until power is re-cycled.
Refer to Drive Motor Electrical
Evaluation in Section 3.7.
The ground board detected armature, field, or pump current Refer to Pump Motor Electrical
9 9 POWER MODULE FAILURE: SYSTEM MONITOR
while function was not commanded. Evaluation in Section 4.7.
Refer to Power Module Electrical
Evaluation in Section 3.8.
The control system detected an EEPROM failure. Personalities
and Machine Setup settings may be reset to default values.
Check / correct all settings and
EEPROM FAILURE – CHECK ALL SETTINGS 9-9 Flash Code
9 9 re-cycle power to clear diffi-
The control system’s EEPROM checksum indicates corruption.
culty.
Retained until EEPROM settings are corrected and power is re-
cycled.

5-20 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The control system has not been configured for the first time.
Use the JLG Analyzer to adjust all
9-9 Flash Code
FUNCTIONS LOCKED OUT – MACHINE NOT CONFIGURED Machine Setup and Personality
9 9 The control system’s EEPROM flag indicates that the vehicle has
settings and re-cycle power to
not been configured (new control system components).
clear difficulty.
Retained until EEPROM flag is cleared and power is re-cycled.
The control system will not function because the Platform
Module Software Version is not compatible with the rest of the
FUNCTIONS LOCKED OUT – PLATFORM MODULE SOFT- system.
Re-program or replace with a
9 9 WARE VERSION IMPROPER 9-9 Flash Code
Version 1.xx module.
The Platform Module reported a Software Major Version that
was not equal to “1”. The control system may resume operation
once the difficulty has been corrected.
The control system will not function because the Power Mod-
ule Software Version is not compatible with the rest of the sys-
tem.
FUNCTIONS LOCKED OUT – POWER MODULE SOFTWARE
9-9 Flash Code Re-program or replace with a
9 9 VERSION IMPROPER
The Power Module reported a Software Major Version that was Version 1.xx module.
not equal to “1”. The control system may resume operation
once the difficulty has been corrected.

The control system will not function because the LSS Module
Software Version is not compatible with the rest of the system.
FUNCTIONS LOCKED OUT – LSS MODULE SOFTWARE 9-9 Flash Code
Re-program or replace with a
9 9 VERSION IMPROPER Machine Setup’s LOAD=1 or 2 AND the LSS Module reported a
Version 7.xx module.
Software Major Version that was not equal to “7”. The control
system may resume operation once the difficulty has been cor-
rected.

3121166 – JLG Lift – 5-21

 ACCESS LEVEL:
CODE 33271

5-22
Analyzer Flow Chart
MENU: ACCESS LEVEL:
ACCESS LEVEL 1 CODE 00000

*
MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES DRIVE LIFT STEER ACCELERATOR GROUND LOAD

*
DRIVE: LIFT: STEER: ACCELERATOR: GROUND: LOAD:
ACCEL 0.1 - 5.0 S ACCEL 0.1 - 5.0 S STATIC 0 - 100% FWD MIN 2.25V HORN 107 DB ACC’Y 0 - 200 KG

*
DRIVE: LIFT: STEER: ACCELERATOR: GROUND: LOAD:
DECEL 0.1 - 10.0 S DECEL 0.1 - 1.0 S DRIVE 0 - 100% FWD MAX 1.20V ALARM 87 DB OVR DBNCE 3.0 S

*
DRIVE: LIFT: ACCELERATOR: LOAD:
MINIMUM 0 - 25% UP MIN 0 - 50% REV MIN 2.75V OVR HOLD 5.0 S

DRIVE: LIFT: ACCELERATOR:

MAXIMUM 0 - 100% UP MAX 0 - 100% REV MAX 3.80V
SECTION 5 - JLG CONTROL SYSTEM

DRIVE: LIFT:
ELEV. MAX 0 - 25% DN MIN 0 - 60%

LIFT:
DN MAX 0 - 100%

* * *
MENU: MODEL NUMBER: MARKET: TILT CUTOUT: DRIVE CUTOUT: CHRGER INTRLOC: GROUND ALARM: LOAD: DRIVE MOTORS:
MACHINE SETUP 1930ES 0 = ANSI USA 0 = NO 0 = NO 0 = DRIVE ONLY 0 = NOT INSTALLED 0 = NOT INSTALLED 0 = PEERLESS

* *

– JLG Lift–
MODEL NUMBER: MARKET: TILT CUTOUT: DRIVE CUTOUT: CHRGER INTRLOC: GROUND ALARM: * LOAD: GROUND ALARM:
2030ES 1 = ANSI EXPORT 1 = YES 1 = YES 1 = DRV & LIFT UP 1 = DESCENT 1 = CUTOUT PLT 1 = ADVANCED DC

MODEL NUMBER: MARKET: GROUND ALARM: * LOAD:

2630ES 2 = CSA 2 = MOTION 2 = CUTOUT ALL

MODEL NUMBER: MARKET:

2646ES 3 = CE
* *
ELEV PROX: BATTERY: FOOTSWITCH:
MODEL NUMBER: MARKET: 0 = NOT INSTALLED 0 = FLOODED 0 = NO
3246ES 4 = AUSTRALIA
ELEV PROX: * BATTERY: FOOTSWITCH: *
MARKET: 1 = INSTALLED 1 = AGM 1 = YES
5 = JAPAN

MENU: CALIBRATIONS: CALIBRATIONS: * CALIBRATIONS: * CALIBRATIONS: *

CALIBRATIONS TILT SENSOR SET ELEV SENSOR LOAD DRIVE CUTOUT

* *
LEVEL VEHICLE: SET ELEV SENSOR: LOAD: DRIVE CUTOUT: *
YES:ENTR, NO:ESC YES:ENTR, NO ESC YES:ENTR, NO:ESC YES:ENTR, NO:ESC

Continued *
UNCALED TILT: SET ELEV SENSOR:
on sheet 2 +X.XX, +Y.YY 0.10 - 1.20V X.XXV

Figure 5-2. Analyzer Flow Chart (Sevcon) - Sheet 1 of 3

3121166
3121166
MENU: ACTIVATE TEST: RUN SYSTEM TEST: RUN SYS TEST: (3) RUN SYS TEST: (3) RUN SYS TEST: (4) RUN SYS TEST: (4) RUN SYS TEST: (4) RUN SYS TEST:
SYSTEM TEST YES:ENTR, NO:ESC TEST VALVES? TEST GND SW? TEST OVLD & ALRM? TEST PLT SW? TEST LEDS & ALRM? TEST PROP CNTRL? TEST COMPLETE

RUN SYSTEM TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST:
LT STEER GND LIFT UP OVERLOAD ON CLOSE STEER LT BATTERY 1 (1/4) CNTRL FWD TO MAX

RUN SYSTEM TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST:
RT STEER GND LIFT DN HORN ON OPEN STEER LT BATTERY 2 (½) CNTRL FWD TO MIN

RUN SYSTEM TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST: RUN SYS TEST:
LIFT UP ALARM ON CLOSE RT STEER BATTERY 3 (3/4) CNTRL BACK TO MX

RUN SYS TEST: RUN SYS TEST: RUN SYS TEST:

OPEN RT STEER BATTERY 4 (FULL) CNTRL BACK TO MN

RUN SYS TEST: RUN SYS TEST:

OPEN IN/OUT SEL SYS DISTRESS ON

RUN SYS TEST: RUN SYS TEST:

CLOSE TRIGGER TILT LAMP ON

RUN SYS TEST: RUN SYS TEST:

CLOSE IN/OUT SEL INDOOR ON

MENU: ACTIVATE TEST: RUN SYSTEM TEST: RUN SYS TEST: RUN SYS TEST:
SYSTEM TEST YES:ENTR, NO:ESC TEST VALVES? OPEN TRIGGER OUTDOOR ON

– JLG Lift –
RUN SYS TEST: RUN SYS TEST:
CLOSE HORN SW OVERLOAD ON

RUN SYS TEST: RUN SYS TEST:

OPEN HORN SW PLAT ALARM ON

RUN SYS TEST:

SELECT DRIVE
Continued
on sheet 3
RUN SYS TEST:
SELECT LIFT

Figure 5-3. Analyzer Flow Chart (Sevcon) - Sheet 2 of 3

5-23
SECTION 5 - JLG CONTROL SYSTEM
5-24
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
PERSONALITIES PLATFORM GROUND TRACTION PUMP SYSTEM ELEV SENSOR VALVES CHARGER

PLATFORM: GROUND: TRACTION: PUMP: SYSTEM: ELEV SENSOR: * VALVES: CHARGER:

DRIVE SEL OPEN LIFT UP OPEN MODE: NEUTRAL MODE: NEUTRAL MODE GROUND ANGLE SNSR XX.XV STEER LT OFF/ON AC (NOT)CONNECTED

PLATFORM: GROUND: TRACTION: PUMP: SYSTEM: ELEV SENSOR: * VALVES:

LIFT SEL OPEN LIFT DN OPEN SPEED 0 - 100% PUMP PWM 0 - 100% BATTERY XX.XV ZEROED X.XXV STEER RT OFF/ON

PLATFORM: TRACTION: PUMP: SYSTEM: * ELEV SENSOR: * VALVES:

STEER LT OPEN DRV VOLT XX.XV PUMP CUR XXX.XA PLT BATT XX.XV PROX SW OPEN LIFT UP OFF/ON

PLATFORM: TRACTION: SYSTEM: ELEV SENSOR: * VALVES:

STEER RT OPEN ARM VOLT XX.XV TILT +X.X +Y.Y PLATFORM STOWED LIFT DN 0 - 100%

PLATFORM: * TRACTION: SYSTEM: * ELEV SENSOR:

IN/OUT OPEN ARM PWM 0 - 100% FIXED TILT +X.X PPS SPEED STOWED

*
SECTION 5 - JLG CONTROL SYSTEM

DIAGNOSTICS: * TRACTION: SYSTEM: ELEV SENSOR:

ZONE A/B OPEN ARM CUR XXX.XA BRAKE ON/OFF CALIB X.XXV

PLATFORM: TRACTION: SYSTEM:

HORN OPEN FLD VOLT SS.SV BRK RELES OPEN

PLATFORM: TRACTION: SYSTEM: *

TRIGGER OPEN FLD PWM 0 - 100% PHP OPEN/CLOSED

PLATFORM: TRACTION: SYSTEM: * *

DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
JOYSTICK 0% FLD CUR XX.XA LT PHP OPEN/CLSD LOAD DATALOG VERSIONS

– JLG Lift–
PLATFORM: * TRACTION: SYSTEM: * *
LOAD: DATALOG: VERSIONS:
FOOTSWITCH OPEN TEMP XXC RT PHP OPEN/CLSD PLT LOAD XXXXKG DRIVE XXH XXM GM SW P?.?

SYSTEM: * *
LOAD: DATALOG: VERSIONS:
PHP RET/EXT/FAULTY PLTGROSS XXXXKG LIFT XXH XXM GM HW REV?

SYSTEM: LOAD: * DATALOG: VERSIONS:

HORN ON/OFF OVERLOADED? YES RENTAL XXH XXM GM SN ?????
Notes:
LOAD: * DATALOG: VERSIONS:
(3) = This option and all below it are CELL 1 XXXXKG ERASE RENTAL? PM SW P?.?

available in Ground Mode only. LOAD: * DATALOG: VERSIONS:

CELL 2 XXXXKG YES:ENTR, NO:ESC PM HW REV?
(4) = This option and all below it are
LOAD: * VERSIONS:
available in Platform Mode only. CELL 3 XXXXKG PM SN?????

* = This option may be available LOAD: * VERSIONS:

CELL 4 XXXXKG POWER MOD V?.??
depending on Machine Setup.
VERSIONS: *
rev 9-14
LSS SW P?.?

VERSIONS: *
LSS HW?

Figure 5-4. Analyzer Flow Chart (Sevcon) - Sheet 3 of 3

3121166
 SECTION 5 - JLG CONTROL SYSTEM

Analyzer Flow Chart

Figure 5-5. Analyzer Flow Chart (ZAPI) - Sheet 1 of 3

3121166 – JLG Lift – 5-25

5-26
SECTION 5 - JLG CONTROL SYSTEM

– JLG Lift–
Figure 5-6. Analyzer Flow Chart (ZAPI) - Sheet 2 of 3

3121166
 SECTION 5 - JLG CONTROL SYSTEM

Figure 5-7. Analyzer Flow Chart (ZAPI) - Sheet 3 of 3

3121166 – JLG Lift – 5-27

 SECTION 5 - JLG CONTROL SYSTEM

5.8 MACHINE MODEL ADJUSTMENT - SEVCON - 1600346 POWER MODULE

Table 5-3. Machine Model Adjustment

(Machines with Sevcon - 1600346 Power Module Only)

Adjustment Adjustment Range 1930ES 2030ES 2630ES 2646ES 3246ES

DRIVE
ACCEL 0.1 - 5.0 (Sec) 0.7 0.7 0.7 0.7 0.7
DECEL 0.1 - 1.0 (Sec) 0.1 0.1 0.1 0.1 0.1
MINIMUM 0 - 25% 0 0 0 0 0
MAXIMUM 0 -100% 100 100 100 100 100
ELEV. MAX. 0 - 25% 18 16 16 20 20
LIFT
ACCEL 0.1 - 5.0 (Sec) 0.5 0.5 0.5 0.5 0.5
DECEL 0.1 - 1.0 (Sec) 0.1 0.1 0.1 0.1 0.1
UP MIN 0 - 50% 20 20 20 20 20
UP MAX 0 - 100% 100 100 100 100 100
DN MIN 1 - 60% 18 45 42 52 52
DN MAX 1 - 100% 60 85 63 80 80
STEER
STATIC 0 - 100% 50 50 50 50 50
DRIVE 0 - 100% 30 30 30 30 30
ACCELERATOR
FWD MIN 2.20 - 2.40 V 2.25 2.25 2.25 2.25 2.25
FWD MAX 1.00 - 1.50 V 1.20 1.20 1.20 1.20 1.20
REV MIN 2.60 - 2.80 V 2.75 2.75 2.75 2.75 2.75
REV MAX 3.50 - 4.00 V 3.80 3.80 3.80 3.80 3.80
GROUND
HORN 87 - 107 dB 107 107 107 107 107
ALARM 87 - 107 dB 87 87 87 87 87
LOAD
ACCY 0 - 200 Kg 0 0 0 0 0
OVR DBNCE 0.0 - 5.0 Sec 3.0 3.0 3.0 3.0 3.0
OVR HOLD 0.0 - 5.0 Sec 5.0 5.0 5.0 5.0 5.0
4150472-I *

* Rev. I - Obsoleted by 1001115626

NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.

5-28 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

5.9 MACHINE MODEL ADJUSTMENT - ZAPI - 1001092456 POWER MODULE

Table 5-4. Machine Model Adjustment
(Machines with ZAPI - 1001092456 Power Module Only)

Adjustment Adjustment Range 1930ES 2030ES 2630ES 2646ES 3246ES

DRIVE
ACCEL 0.1 - 5.0 (Sec) 0.7 0.7 0.7 0.7 0.7
DECEL 0.1 - 1.0 (Sec) 0.1 0.1 0.1 0.1 0.1
MINIMUM 0 - 25% 0 0 0 0 0
MAXIMUM 0 -100% 100 100 100 100 100
ELEV. MAX. 0 - 25% 25 25 25 25 25
LIFT
ACCEL 0.1 - 5.0 (Sec) 0.5 0.5 0.5 0.5 0.5
DECEL 0.1 - 1.0 (Sec) 0.1 0.1 0.1 0.1 0.1
UP MIN 0 - 50% 20 20 20 20 20
UP MAX 0 - 100% 100 100 100 100 100
DN MIN 1 - 60% 45 45 45 45 45
DN MAX 1 - 100% 75 75 75 75 75
STEER
STATIC 0 - 100% 70 70 70 70 70
DRIVE 0 - 100% 30 30 30 30 30
ACCELERATOR
FWD MIN 2.20 - 2.40 V 2.23 2.23 2.23 2.23 2.23
FWD MAX 1.00 - 1.50 V 1.19 1.19 1.19 1.19 1.19
REV MIN 2.60 - 2.80 V 2.74 2.74 2.74 2.74 2.74
REV MAX 3.50 - 4.00 V 3.78 3.78 3.78 3.78 3.78
GROUND
HORN 10 - 100% 94 94 94 94 94
ALARM 10 - 100% 19 19 19 19 19
LOAD
ACCY 0 - 200 Kg 0 0 0 0 0
OVR DBNCE 0.0 - 5.0 Sec 3.0 3.0 3.0 3.0 3.0
OVR HOLD 0.0 - 5.0 Sec 5.0 5.0 5.0 5.0 5.0
1001115627-D

NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.

3121166 – JLG Lift – 5-29

 SECTION 5 - JLG CONTROL SYSTEM

5.10 MACHINE CONFIGURATION PROGRAMMING INFORMATION - SEVCON - 1600346

NOTE: When configuring an ES scissors machine, the machine configuration must be completed before any personality set-
tings can be changed. Changing the personality settings first and then changing the model number of the machine con-
figuration will cause the personality settings to return to default.
Shaded entries are not available for the selected Market.

Table 5-5. Machine Configuration Programming Information

(Machines with Sevcon - 1600346 Power Module Only)

Configuration * Market Default Setting

Setting Description
Digit 0 1 2 3 4 5
1 1930ES
2 2030ES
1 (Set to your applicable ES Model
3 2630ES
(Model #) 1 through 5)
4 2646ES
5 3246ES
0 ANSI USA
1 ANSI EXPORT
2 2 CSA 0 - (ANSI USA)
(Market *) 3 CE (Set to your applicable market)
4 AUSTRALIA
5 JAPAN
3 0 NO - Drive and lift up not prevented while tilted (Ground and Platform Mode).
1 1 1 0 1 1
(Tilt Cutout) 1 YES - Drive and lift up prevented while tilted (Ground and Platform Mode).
4 0 No - Drive and lift up not prevented while elevated.
0
(Drive Cutout) 1 Yes - Drive and lift up prevented while elevated.
0 DRIVE ONLY - Drive motion prevented while vehicle is charging.
5
Drive and Lift Up - Drive and lift up motions are prevented while vehicle is charging. 0 0 0 0 0 0
(Charger Interlock)
1 Required for CE.
0 NOT INSTALLED - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS
enabled, and as a horn.
6 1 DESCENT - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS enabled,
2 2 2 0 2 2
(Ground Alarm) as a horn and during Lift Down motion.
2 MOTION - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS enabled,
as a horn and during Drive and Lift motion.
0 NOT INSTALLED - Load Sensing System (LSS) is not fitted to the vehicle.
7 1 CUTOUT PLT - Load Sensing System (LSS) is fitted and Platform Controls are prevented in
(LSS - the event of an Overload. Ground Controls remain functional. This is the default setting for
0 1 0 1 0 1
Load Sensing CE machines.
System) 2 CUTOUT ALL - Load Sensing System (LSS) is fitted. Platform and GRound Controls are pre-
vented in the event of an overload.
8 0 PEERLESS - Vehicle is fitted with Peerless drive motors.
1
(Drive Motors) 1 ADVANCED DC - Vehicle is fitted with ADvanced DC drive motors.
0 NOT INSTALLED - Vehicle is not fitted with an Elevation Prox Sensor. Vehicle has Left and
9 Right Brake Release Outputs, and Maintained Brake Release functionality.
0
(Elev Prox) 1 INSTALLED - Vehicle is fitted with an Elevation Prox Sensor (original ES-Series). Vehicle has
a single Brake Release Output, and Momentary Brake Release functionality.
10 0 FLOODED - Batteries are conventional lead-acid type.
0
(Battery) 1 AGM - Batteries are absorbed glass mat type.
11 0 NO - Vehicle is not fitted with a footswitch
0 0 0 0 0 1
(Footswitch) 1 YES - Vehicle is fitted with a footswitch
4150473-F

5-30 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

5.11 MACHINE CONFIGURATION PROGRAMMING INFORMATION - ZAPI - 1001092456

NOTE: When configuring an ES scissors machine, the machine configuration must be completed before any personality set-
tings can be changed. Changing the personality settings first and then changing the model number of the machine con-
figuration will cause the personality settings to return to default.
Shaded entries are not available for the selected Market.

Table 5-6. Machine Configuration Programming Information

(Machines with ZAPI - 1001092456 Power Module Only)

Configuration * Market Default Setting

Setting Description
Digit 0 1 2 3 4 5
1 1930ES
2 2030ES (Set to your applicable ES Model
1
3 2630ES 1 through 5)
(Model #)
4 2646ES
5 3246ES
0 ANSI USA
1 ANSI EXPORT
2 2 CSA 0 - (ANSI USA)
(Market *) 3 CE (Set to your applicable market)
4 AUSTRALIA
5 JAPAN
3 0 NO - Drive and lift up not prevented while tilted (Ground and Platform Mode).
1 1 1 0 1 1
(Tilt Cutout) 1 YES - Drive and lift up prevented while tilted (Ground and Platform Mode).
4 0 NO - Drive and lift up not prevented while elevated.
0
(Drive Cutout) 1 YES - Drive and lift up prevented while elevated.
0 DRIVE ONLY - Drive motion prevented while vehicle is charging.
5
DRIVE AND LIFT UP - Drive and lift up motions are prevented while vehicle is charging. 0 0 0 0 0 0
(Charger Interlock)
1 Required for CE.
0 NOT INSTALLED - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS
enabled, and as a horn.
6 1 DESCENT - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS enabled,
2 2 2 0 2 2
(Ground Alarm) as a horn and during Lift Down motion.
2 MOTION - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS enabled,
as a horn and during Drive and Lift motion.
0 NOT INSTALLED - Load Sensing System (LSS) is not fitted to the vehicle.
7 1 CUTOUT PLT - Load Sensing System (LSS) is fitted and Platform Controls are prevented in
(LSS - the event of an Overload. Ground Controls remain functional. This is the default setting for
0 1 0 1 1 1
Load Sensing CE machines.
System) 2 CUTOUT ALL - Load Sensing System (LSS) is fitted. Platform and GRound Controls are pre-
vented in the event of an overload.
8 0 FLOODED - Batteries are conventional lead-acid type.
0
(Battery) 1 AGM - Batteries are absorbed glass mat type.
9 0 NO - Vehicle is not fitted with a footswitch
0 0 0 0 0 1
(Footswitch) 1 YES - Vehicle is fitted with a footswitch
1001115626-C

3121166 – JLG Lift – 5-31

 SECTION 5 - JLG CONTROL SYSTEM

NOTES:

5-32 – JLG Lift– 3121166