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 electri-
cal systems.
The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir-
cuit is lacking hydraulic oil and electrical control power. This can be ascertained by overriding the bypass valve (mechani-
cally or electrically) so that oil is available to the function valve, then overriding the function valve mechanically. 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 Adjust-
ment (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.
0 0 ALARM SOUNDING--TILTED AND ABOVE ELEVA- Platform is elevated and the chassis is not level.
TION Platform Position Sensor (PPS) elevation status is ele-
vated and the vehicle is tilted and machine setup’s TILT
CUTOUT is 0=YES.
No motion restrictions.
0 0 DRIVING AT CUTBACK -- ABOVE ELEVATION Platform is elevated and the machine is in the drive mode of
operation.
In platform mode, Platform Position Sensor (PPS) eleva-
tion status is elevated and the vehicle is driving and the
drive speed is drive elevated.
Driving at elevated speed.
0 0 DRIVE & LIFT UP PREVENTED -- TILTED & Driving is not possible since the platform is elevated and
ELEVATED the chassis is not level.
In Platform Mode, Platform Position Sensor (PPS) eleva-
tion status is elevated and the vehicle is tilted and machine
setup’s TILT CUTOUT is 1=YES.
Drive prevented.
0 0 LIFT UP PREVENTED -- MAX HEIGHT ZONE A Applicable to 3246ES configured for the Zone A/B Capac-
ity Selection, and operating on Zone A. The vehicle has
reached the maximum height and further lift up motion is
not possible.
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.

3121166 – JLG Lift – 5-9

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

FLASH
HELP MESSAGE CAUSE POSSIBLE RESOLVE
CODE
0 0 DRIVING AT CUTBACK -- POTHOLE STILL While stowed, drive speed is reduced (due to lower ground Clear the obstacle blocking
ENGAGED clearance) since the control system detected that the pot- the pot-hole protection mech-
hole protection mechanism is deployed (failed to retraced). anism, repair the mechanical
In platform mode with a healthy elevation sensor, elevation problem, re-adjust the pot-
sensor less than 0.15V and the elevation prox closed and hole limit switches, or repair
pot-hole protection’s PHP switches detect down. the wiring to correct the prob-
In platform mode with an unhealthy elevation sensor, the lem.
elevation prox is closed AND pot-hole protection’s PHP
switches detect down.
0 0 FUNCTIONS LOCKED OUT -- SYSTEM POWERD After 2 hours without activity, the control system enters a Check batteries charge, con-
DOWN low-power state to preserve battery charge. dition, etc. Normal operation
should resume after a power
cycle.
0 0 DRIVE PREVENTED -- ELEVATED AND ABOVE The Drive Cutout functionality is enabled, and the platform Check elevation switches
DRIVE CUTOUT HEIGHT is elevated above the calibrated cutout height. Check pothole switches.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
“Healthy” AND the Elevation Sensor’s Zeroed Voltage is
Greater 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.
2 1 STARTUP This help message is issued at each power-up. This serves
to indicate which messages have been recorded in logged
help since the last power-up event.
No motion restrictions.
No motions restricted.
2 1 KEYSWITCH FAULTY -- PLATFORM & GROUND The platform and ground mode inputs from the keyswitch Re-cycle power once the
ACTIVE TOGETHER are active at the same time. The control system will default problem has been resolved to
to ground mode when if this happens. The keyswitch and clear this difficulty.
wiring inside the ground control box should be examined /
repaired.
Platform EMS digital input energized and ground mode
select 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.
2 2 FUNCTION PROBLEM -- HORN PERMANENTLY Horn switch in the platform control box was closed during Release or repair the switch to
SELECTED power-up. clear the message.
In platform mode, the Indoor/Outdoor switch digital input is
energized and power-up is active. Retained until either is
momentarily de-energized.
Previously selected Indoor/Outdoor mode maintained.
2 2 FUNCTION PROBLEM -- INDOOR / OUTDOOR Indoor / Outdoor switch in the platform control box was Release or repair the switch to
PERMANENTLY SELECTED closed during power-up. clear the message.
In Platform Mode, the Indoor / Outdoor Switch Digital Input
is Energized and Power-up is Active. Retained until Digital
Input is momentarily De-energized.
Previously selected Indoor / Outdoor Mode maintained

5-10 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

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

3121166 – JLG Lift – 5-11

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

FLASH
HELP MESSAGE CAUSE POSSIBLE RESOLVE
CODE
2 2 TRIGGER CLOSED TOO LONG WHILE IN NEU- Trigger switch in the platform control box was closed for Release switch or repair the
TRAL more than ten seconds while the joystick (accelerator) was switch / wiring to clear the diffi-
in the neutral position (centered). culty.
In Platform Mode, the Trigger Digital Input was Energized
for 10,000mS AND Drive was In-Active AND Lift was In-
Active. Retained until the Trigger Digital Input is momen-
tarily De-energized.
Drive, Steer, & Lift Prevented.

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

5-12 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

FLASH
HELP MESSAGE CAUSE POSSIBLE RESOLVE
CODE
Help messages with the 2-5 flash code indicate that a function is prevented due to a cutout.
2 5 ELEV ANGLE SENSOR FAULTY — NOT MOUNTED The input voltage from the sensor that measures lower arm Check mounting, review sen-
OR VOLTAGE OUT OR RANGE motion is outside acceptable range. This may be caused by sor wiring against the electri-
improper sensor mounting, difficulty with the sensor wiring, cal schematic, or replace the
or a faulty sensor. sensor to clear the message.
The elevation sensor is unhealthy
Platform height assumed to be full elevation.
2 5 ELEV ANGLE SENSOR HAS NOT BEEN CALI- The Elevation Sensor’s Calibration EEPROM is set to the Calibrate the elevation angle
BRATED signature implanted by the In-Circuit Test Fixture. Retained sensor using the calibration
until Calibration EEPROM is over-written by a valid calibra- procedure to clear the mes-
tion. sage.
Platform Height assumed to be Full Elevation.
The Elevation Proximity Switch is Open to indicate that the
Platform is Elevated, but the Elevation Sensor’s Voltage
indicates that the Platform is Stowed. To be conservative,
the control system will assume that the Platform is Ele-
vated.
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.
2 5 DRIVE PREVENTED — CHARGER CONNECTED Driving is not possible since the vehicle is charging and it is Disconnect battery charger
configured to only allow lifting.
In Platform Mode, the Battery Charger is Charging AND the
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 0=DRIVE ONLY.
Drive & Steer Prevented
2 5 DRIVE & LIFT UP PREVENTED — CHARGER CON- Driving and lifting are not possible since the vehicle is Disconnect battery charger
NECTED charging and it is configured to prevent all motion.
In Platform Mode, the Battery Charger is Charging AND the
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.
2 5 PLATFORM OVERLOADED While the Load Sensing System is enabled, the platform Remove excess weight from
load measured by the Load Sensing System is excessive. platform.
Functions from platform control are prevented, and func-
tions from ground control may be prevented, depending on
machine configuration.
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).
2 5 DRIVE PREVENTED — POTHOLE NOT ENGAGED While elevated, driving is not possible since the control sys- Clear the obstacle blocking
tem detected that the pot-hole protection mechanism failed the pot-hole protection mech-
to deploy. anism, repair the mechanical
In Platform Mode with a Healthy Elevation Sensor, the Ele- problem, re-adjust the pot-
vation Sensor Voltage > 0.15V AND Pot-Hole Protection’s hole limit switches, or repair
PHP Switches detect Up. the wiring to correct the prob-
In Platform Mode with an Unhealthy Elevation Sensor, the lem.
Elevation Prox Sensor is Open (no Arm Detected) AND
Pot-Hole 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
2 5 ELEV PROX PERMANENTLY CLOSED — CHECK The Elevation Proximity Switch is closed to indicate that the Check elevation switches.
PROX AND ANGLE ADJUSTMENT platform is stowed, but the elevation sensor’s voltage indi- Replace if necessary.
cates that the platform is elevated. To be conservative, the
control system will assume that the platform is elevated,
and the drive speed will be restricted to elevated.
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.
2 5 DRIVE & LIFT PREVENTED — BRAKES ELECTRI- The manual brake release has been activated to allow the Disengage the manual brake
CALLY RELEASED FOR TOWING vehicle to be towed. release.
Brake release digital input is energized
Drive and Lift Prevented
2 5 DRIVE PREVENTED — ELEVATED ABOVE DRIVE The Drive Cutout functionality is enabled, and the platform Check elevation switches
CUTOUT HEIGHT is elevated above the calibrated cutout height. Check pothole switches.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
“Healthy” AND the Elevation Sensor’s Zeroed Voltage is
Greater Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.

2 5 MODEL CHANGED -- HYDRAULICS SUSPENDED The model selection has been changed. Check ANALYZER ->
- CYCLE EMS MACHINE SETUP -> MODEL
NUMBER.
Replace ground board.
2 5 DRIVE PREVENTED -- BRAKES NOT RELEASING While driving on a level surface, armature current was > Ensure vehicle is not stuck on
150A for five seconds. Brakes assumed to not be releasing something preventing move-
properly. ment. Check/repair drive
motor wiring, brakes or
mechanical issues.
Help messages with the 3-1 flash code indicate that a contactor did not close when energized.
3 1 OPEN CIRCUIT LINE CONTACTOR The Power Module’s line contactor drive circuitry passed Refer to CANbus documenta-
power-up self-tests, but the line contactor did not close tion for Power Module Mes-
when energized. sage - Status.
The Power Module is reporting a “Contactor Did Not Close”
Fault Code (15d).
Drive, Steer, & Lift Up Prevented.
3 1 CONTACTOR DRIVER PERMANENTLY OFF The Power Module’s Line Contactor drive circuitry failed to Refer to CANbus documenta-
energize during power-up self-tests. tion for Power Module Mes-
The Power Module is reporting a “Contactor Driver 1 Per- sage - Status.
manently Off” Fault Code (22d).
Drive, Steer, & Lift Up Prevented.
Help messages with the 3-2 flash code indicate that a contactor did not open when de-energized.
3 2 LINE CONTACTOR MISWIRED ON OR WELDED The Power Module’s Line Contactor Drive Circuitry passed Refer to CANbus documenta-
power-up self-tests, but the line contactor did not open tion for Power Module Mes-
when de-energized. sage - Status.
The Power Module is reporting a “Contactor Welded” Fault
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
3 2 CONTACTOR DRIVER PERMANENTLY ON The Power Module’s Line Contactor Drive Circuitry failed Refer to CANbus documenta-
to de-energize during power-up self-tests. tion for Power Module Mes-
The Power Module is reporting a “Contactor Driver 1 Per- sage - Status.
manently On” Fault Code (23d). Refer to CANbus docu-
mentation 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.
3 3 BRAKE SHORT TO BATTERY Voltage was detected on the brake solenoid when the out-
put driver was commanded off during power-up.
Brake INPUT driven Low AND Brake STAT detected Low
during power-up.
Drive, Steer, & Lift Prevented.
3 3 BRAKE OPEN CIRCUIT Current flow to the brake solenoid was not detected during
normal brake operation.
Brake INPUT driven High (normal operation) AND Brake
STAT detected Low.
Drive & Steer Prevented
3 3 LIFT UP SHORT TO BATTERY Voltage was detected on the lift up solenoid when the out-
put driver was commanded off during power-up.
Lift Up INPUT driven Low AND Lift Up STAT detected Low
during power-up.
Drive, Steer, & Lift Up Prevented.
3 3 LIFT UP OPEN CIRCUIT Current flow to the lift up solenoid was not detected during
power-up.
Lift Up INPUT driven High (momentarily) AND Lift Up STAT
detected Low during power-up.
No motion interlocks.
3 3 LIFT DN SHORT TO BATTERY Voltage was detected on the lift down solenoid when the
output driver was commanded off during power-up.
Lift Down INPUT driven Low AND Lift Down STAT detected
Low during power-up.
No motion interlocks.
3 3 LIFT DN OPEN CIRCUIT Current flow to the lift down solenoid was not detected dur-
ing normal lift down motion.
Lift Down INPUT driven High (normal operation) AND Lift
Down STAT detected Low.
Lift Up Prevented.
3 3 STEER LEFT SHORT TO BATTERY Voltage was detected on the steer left solenoid when the
output driver was commanded off during power-up.
Left Turn INPUT driven Low AND Left Turn STAT detected
Low during power-up.
Drive & Steer Prevented.
3 3 STEER LEFT OPEN CIRCUIT Current flow to the steer left solenoid was not detected dur-
ing power-up.
Left Turn INPUT driven High (momentarily) AND Left Turn
STAT detected Low 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
3 3 STEER RIGHT SHORT TO BATTERY Voltage was detected on the steer right solenoid when the
output driver was commanded off during power-up.
Right Turn INPUT driven Low AND Right Turn STAT
detected Low during power-up.
Drive & Steer Prevented.
3 3 STEER RIGHT OPEN CIRCUIT Current flow to the steer right solenoid was not detected
during power-up.
Right Turn INPUT driven High (momentarily) AND Right
Turn STAT detected Low during power-up.
Drive & Steer Prevented.
3 3 GROUND OVERLOAD LAMP SHORT TO BAT- While the load sensing system was enabled, voltage was
TERY detected on the ground control box’s overload lamp when
the output driver was commanded off during power-up.
Ground Overload INPUT driven Low AND Ground Over-
load STAT detected Low during power-up AND [Machine
Setup’s LOAD set to 1=CUTOUT PLT OR 2=CUTOUT
ALL].
No motion interlocks.
3 3 GROUND OVERLOAD LAMP OPEN CIRCUIT While the Load Sensing System was enabled, current flow
to the ground control box’s overload lamp was not detected
during power-up.
Ground Overload INPUT driven High (momentarily) 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.
3 3 GROUND ALARM SHORT TO BATTERY While enabled, voltage was detected on the ground alarm
when the output driver was commanded off during power-
up.
Ground Alarm INPUT driven Low AND Ground Alarm STAT
detected Low during power-up AND [Machine Setup’s
GROUND ALARM set to 1=DECENT OR 2=MOTION].
No motion interlocks.
3 3 LEFT BRAKE SHORT TO BATTERY The ground board detected voltage while the left brake was Check for continuity through
commanded off. this circuit. Inspect the wiring
for physical damage.
Replace ground board.
3 3 LEFT BRAKE OPEN CIRCUIT Current flow to the left brake solenoid was not detected dur- Check for continuity through
ing normal left brake operation. this circuit. Inspect the wiring
for physical damage.
Replace ground board.
3 3 RIGHT BRAKE SHORT TO BATTERY Voltage was detected on the right brake solenoid when the Check for continuity through
ground board output was commanded off during power-up. this circuit. Inspect the wiring
for physical damage.
Replace ground board.
3 3 RIGHT BRAKE OPEN CIRCUIT The ground board did not detect current flow to the right Check for continuity through
brake during normal operation. this circuit. Inspect the wiring
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
Help messages with the 4-2 flash code indicate a thermal problem.
4 2 POWER MODULE TOO HOT — PLEASE WAIT The Power Module for drive, steer, and lift up has reached
thermal cutout. Allow to cool by powering down.
The power Module is reporting a "Unit Too Hot" fault code.
4 2 DRIVING AT CUTBACK -- POWER MODULE CUR- The drive portion of the Power Module has reached ther-
RENT LIMIT mal limit. Allow to cool by waiting for temperature to fall.
The Power Module is reporting a "I2T Drive Current LImit"
fault code.
4 2 LIFT UP AT CUTBACK -- POWER MODULE CUR- The lift up portion of the power module has reached ther-
RENT LIMIT mal limit. Allow to cool by waiting for temperature to fall.
The POwer Module is reporting "I2Pump Current LImit"
fault code.
Help messages with the 4-4 flash code indicate a battery supply problem.
4 4 BATTERY VOLTAGE TOO LOW — SYSTEM SHUT- Battery Voltage momentarily dropped below 14.5V. With a Recharge batteries or check
DOWN low battery charge, this can occur during heavy current for damaged batteries.
demand due to drive, steer, or lift up.
The Power Module is reporting a “Low Battery” Fault Code
(7d).
Drive, Steer, & Lift Up Prevented
4 4 BATTERY VOLTAGE TOO HIGH — SYSTEM SHUT- The Power Module momentarily measured excessively This may be due to improper
DOWN high battery voltage (>37.0v) and the ground module de- battery charging or incorrect
energized the ignition relay to protect system devices. voltage batteries being used.
The Power Module is reporting a “High Battery” Fault Code
(8d) OR a “High Battery without Line” Fault Code (10d). In
response, the Ground Module shall de-energize the Igni-
tion Relay and suppress all Help Messages caused by the
lack of Ignition Signal. This fault is latched until the next
power-cycle.
Drive, Steer, & Lift Prevented.
4 4 LSS BATTERY VOLTAGE TOO HIGH While the Load Sensing System is enabled, the Load Sens- This may be due to improper
ing System module measured battery voltage >34.0Vdc, battery charging or incorrect
which may compromise ability to predict weight. voltage batteries being used.
LSS Module Message — Status Message (0x81) is report-
ing “BATT TOO HIGH” AND [Machine Setup’s LOAD is set
to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Vehicle
assumed to be Overloaded.
4 4 LSS BATTERY VOLTAGE TOO LOW While the Load Sensing System is enabled, the Load Sens- Recharge batteries or check
ing System module measured battery voltage <9.0vdc, for damaged batteries.
which may compromise ability to predict weight. With a low
battery charge, this can occur during heavy current
demand due to drive, steer, or lift up.
LSS Module Message — Status Message (0x81) is report-
ing “BATT TOO LOW” AND [Machine Setup’s LOAD is set
to 1=CUTOUT 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. Nor-
mal operation shall resume if difficulty is resolved.
6 6 CANBUS FAILURE: POWER MODULE The control system failed to receive messages from the Check wiring at the ground
Power Module. control box and power mod-
Power Module Message — Status (0x24) not received for ule. Recycle power to clear
1000mS or Power Module is reported a “CANbus Bus Diffi- difficulty.
culty” Fault Code (0x09).
Drive, Steer, & Lift Up Prevented.
6 6 CANBUS FAILURE: PLATFORM MODULE In Platform Mode, the control system failed to receive mes- Check wiring at the platform
sages from the platform module. and ground control boxes.
Digital Input Message — Motion (0x00) not received for Check wiring along scissor
1000mS AND Platform Mode selected. Retained until arms leading up to Platform.
power is re-cycled.
All Platform functions Prevented. Normal operation from
Ground Mode.
6 6 CANBUS FAILURE: LOAD SENSING SYSTEM With the Load Sensing System enabled, the control system Check wiring at the Load
MODULE failed to receive messages from the Load Sensing System Sensing System Module and
Module. along scissor arms leading up
LSS Module Message — Load Cell Message (0x80) not to platform.
received for 1000mS AND [Machine Setup’s LOAD set to
1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained until
power is re-cycled.
Vehicle assumed to be Overloaded.
6 6 ACCESSORY CAN COMMUNICATION LOST A JLG Accessory Module has failed to maintain CANbus Refer to documentation for the
communications with the ground module. JLG Accessory to clear diffi-
The control system received Accessory Message — Control culty.
1 from an Accessory Module, but failed to receive another
within 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.
6 7 ACCESSORY FAULT A JLG Accessory Module has encountered a fault condi- Refer to documentation for the
tion and reported it via the host control system. JLG Accessory to clear diffi-
Accessory Message — Control 1’s Request Accessory culty.
Fault flag is set to YES. Retained or cleared based on sta-
tus of flag.
No motion interlocks.

Help messages with the 7-7 flash code indicate motor problems.
7 7 OPEN-CIRCUIT DRIVE MOTOR FIELD WIRING The Power Module detected an error in the power wiring Check power wiring and re-
(F1 & F2 Terminals) for the drive motors. cycle power to clear difficulty.
The Power Module is reporting a “Field Open Circuit” Fault
Code (16d). Retained until power is re-cycled.
Drive & Steer Prevented

5-18 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

FLASH
HELP MESSAGE CAUSE POSSIBLE RESOLVE
CODE
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 indicated channel.
8 1 LSS CELL #1 ERROR Cell #1’s Bridge <2Vdc, >3Vdc, or could the LSS Module This situation indicates that
could not read Cell #1’s Internal Memory. the sensor is unplugged, or
8-1 Flash Code the sensor is damaged.
LSS Module Message — Status Message (0x81) is report-
ing “CELL 1 ERROR” AND [Machine Setup’s LOAD is set
to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
8 2 LSS CELL #2 ERROR Cell #2’s Bridge <2Vdc, >3Vdc, or could the LSS Module This situation indicates that
could not read Cell #2’s Internal Memory. the sensor is unplugged, or
8-2 Flash Code the sensor is damaged.
LSS Module Message — Status Message (0x81) is report-
ing “CELL 2 ERROR” AND [Machine Setup’s LOAD is set
to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
8 3 LSS CELL #3 ERROR Cell #3’s Bridge <2Vdc, >3Vdc, or could the LSS Module This situation indicates that
could not read Cell #3’s Internal Memory. the sensor is unplugged, or
8-3 Flash Code the sensor is damaged.
LSS Module Message — Status Message (0x81) is report-
ing “CELL 3 ERROR” AND [Machine Setup’s LOAD is set
to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
8 4 LSS CELL #4 ERROR Cell #4’s Bridge <2Vdc, >3Vdc, or could the LSS Module This situation indicates that
could not read Cell #4’s Internal Memory. the sensor is unplugged, or
8-4 Flash Code the sensor is damaged.
LSS Module Message — Status Message (0x81) is report-
ing “CELL 4 ERROR” AND [Machine Setup’s LOAD is set
to 1=CUTOUT 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 addi-
tional information about the difficulty.
9 1 LSS WATCHDOG RESET The Watchdog Timer on Load Sensing System Module’s Re-cycle power to clear diffi-
microprocessor was triggered by exposure to excessive culty
electrical noise, or by a hardware difficulty.
9-1 Flash Code
LSS Module Message — Status Message (0x81) is report-
ing “WATCHDOG RST” AND [Machine Setup’s LOAD is
set to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained
until power is re-cycled.
No motion interlocks.
9 2 LSS EEPROM ERROR Memory used to retain settings on Load Sensing System After resolution, re-cycle
Module has been corrupted and must be reset by verifying power to clear difficulty.
all entries / re-calibrating.
9-2 Flash Code
LSS Module Message — Status Message (0x81) is report-
ing “EEPROM ERROR” AND [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

3121166 – JLG Lift – 5-19

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

FLASH
HELP MESSAGE CAUSE POSSIBLE RESOLVE
CODE
9 3 LSS HAS NOT BEEN CALIBRATED 9-3 Flash Code Calibrate the Load Sensing
The Load Sensing System’s Calibration EEPROM for System using the calibration
Empty Platform Load is set to Never Set (signature procedure to clear the mes-
implanted by the In-Circuit Test Fixture) AND [Machine sage.
Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL]. Retained until Calibration EEPROM is over-written
by a valid calibration.
Vehicle assumed to be Overloaded.
9 9 LSS INTERNAL ERROR — PIN EXCITATION The Excitation Voltage for the Load Sensors < 4.25V. The sensors may be exces-
9-9 Flash Code sively loading the Excitation
LSS Module Message — Status Message (0x81) is report- Supply due to wiring damage,
ing “INTERNAL ERROR — PIN EXCITATION < 4.25V” AND or the Load Sensing System
[Machine Setup’s LOAD is set to 1=CUTOUT PLT OR Module may have hardware
2=CUTOUT ALL]. Retained until power is re-cycled. difficulty.
Vehicle assumed to be Overloaded.
9 9 LSS INTERNAL ERROR — DRDY MISSING FROM The DRDY Interrupt from the Load Sensing System Mod- This may indicate Load Sens-
A/D ule’s A/D Converter is missing. ing System Module hardware
9-9 Flash Code difficulty.
LSS Module Message — Status Message (0x81) is report-
ing “INTERNAL ERROR — DRDY INTERRUPT FROM A/
D” AND [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.
9 9 POWER MODULE FAILURE: PERSONALITY The Power Module detected an out-of-range or corrupt Reset control system Person-
RANGE ERROR personality setting. alities to default settings to
9-9 Flash Code clear difficulty.
The Power Module is reporting a “Configuration Range”
Fault Code (11d) OR a “Configuration CRC” Fault Code
(12d) OR a “Motor Setup” Fault Code (13d). Retained until
power is re-cycled.
9 9 POWER MODULE FAILURE: INTERNAL ERROR The Power Module detected an internal error via self-test. Re-cycle power to clear diffi-
9-9 Flash Code culty.
The Power Module is reporting a “Two Direction” Fault
Code (4d) OR a “Sequence” Fault Code (5d) OR a “CAN-
bus Input” 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.
9 9 POWER MODULE FAILURE: CHECK POWER The Power Module detected an error in the Power Wiring Check wiring and motors or
CIRCUITS OR MOSFET SHORT CIRCUIT for the Drive or Pump. Alternately, the Power Module has replace the Power Module.
failed a self-test. Re-cycle power to clear diffi-
9-9 Flash Code culty.
The Power Module is reporting an “Armature MOSFET
Short Circuit” Fault Code (17d) OR an “Armature MOS-
FET’s Off” Fault 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.

5-20 – JLG Lift– 3121166

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

FLASH
HELP MESSAGE CAUSE POSSIBLE RESOLVE
CODE
9 9 POWER MODULE FAILURE: SYSTEM MONITOR The ground board detected armature, field, or pump cur- Refer to Drive Motor Electrical
rent while function was not commanded. Evaluation in Section 3.7.
Refer to Pump Motor Electri-
cal Evaluation in Section 4.7.
Refer to Power Module Elec-
trical Evaluation in Section
3.8.
9 9 EEPROM FAILURE — CHECK ALL SETTINGS The control system detected an EEPROM failure. Person- Check / correct all settings and
alities and Machine Setup settings may be reset to default re-cycle power to clear diffi-
values. culty.
9-9 Flash Code
The control system’s EEPROM checksum indicates cor-
ruption. Retained until EEPROM settings are corrected
and power is re-cycled.
9 9 FUNCTIONS LOCKED OUT — MACHINE NOT The control system has not been configured for the first Use the JLG Analyzer to
CONFIGURED time. adjust all Machine Setup and
9-9 Flash Code Personality settings and re-
The control system’s EEPROM flag indicates that the vehi- cycle power to clear difficulty.
cle has not been configured (new control system compo-
nents). Retained until EEPROM flag is cleared and power
is re-cycled.
9 9 FUNCTIONS LOCKED OUT — PLATFORM MOD- The control system will not function because the Platform Re-program or replace with a
ULE SOFTWARE VERSION IMPROPER Module Software Version is not compatible with the rest of Version 1.xx module.
the system.
9-9 Flash Code
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.
9 9 FUNCTIONS LOCKED OUT — POWER MODULE The control system will not function because the Power Re-program or replace with a
SOFTWARE VERSION IMPROPER Module Software Version is not compatible with the rest of Version 1.xx module.
the system.
9-9 Flash Code
The Power Module reported a Software Major Version that
was not equal to “1”. The control system may resume oper-
ation once the difficulty has been corrected.

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

3121166 – JLG Lift – 5-21