JLG SMART SYSTEM 1532E User manual

WORLD HEADQUARTERS
JLG INDUSTRIES, INC.
1 JLG Drive
McConnellsburg, PA 17233-9511
USA
Telephone: [phone]
Fax: [phone]
EUROPEAN OFFICE
JLG INDUSTRIES (EUROPE)
Kilmartin Place,
Tannochside Park,
Uddingston, Scotland, G71 5PH
Telephone: [phone]
Fax: [phone]
AUSTRALIAN OFFICE
JLG INDUSTRIES (AUSTRALIA)
P.0. Box 972
11 Bolwarra Road
Port MacQuarie
N.S.W. 44
Australia
Telephone: [phone]
Fax: [phone]
Revised August, 1998
June, 1996 PRINTED IN U.S.A. 3120442
JLG SMART System™
Analyzer Kit
Instruction Manual
BS EN ISO
9
001 CertificateNo.6
9
1
7
MODELS
1532E
1932E
2033E
2046E
2646E
2658E

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
3120442 – JLG Sizzor – 1-1
SECTION 1. JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS
(1600258 CONTROLLER).
INTRODUCTION
The JLG designed SMART System™ is a 24 Volt multiplex motor control unit installed on the electric scissor lift models
1532E, 1932E, 2033E, 2046E, 2646E and 2658E.
The SMART System™ has reduced the need for exposed terminal strips, diodes and trimpots and provides simplicity in
viewing and adjusting the various personality settings for smooth control of: acceleration, deceleration, creep and max-
speed for the lift, drive, steering and optional power deck functions. The function select membrane board, in the upper con-
trol box, also eliminates the need for toggle switches and a separate power enable button as this feature is built into each
function select button on the board itself.
The lift, drive and optional power deck functions are controlled by a joystick, with steering being controlled by a rocker
switch built into the top of the joystick. Drive, lift, and the optional power deck functions are selected by first pushing the
appropriate momentary select buttons on the membrane board and then moving the joystick either in the “A” or “B” direc-
tion. If the joystick is not activated within three seconds of selecting a function, it will be necessary to re-select a function.
High drive and positive traction are used in conjunction with the drive function.
All motor controllers with a date code prior to 9808 have a power saving feature built into the motor controller to shut off
power to the platform controls after ten minutes of idle time. All motor controllers manufactured with a date code after 9808
are featured with an approximate 10 seconds of idle time before the main contactor will open. To reset the system, you sim-
ply select a function or recycle the platform emergency stop button. The motor controller will control current output, as pro-
grammed for smooth operation and maximum cycle time. Ground control speeds for platform lift and the optional power
deck are also programmed into the motor controller. The motor controller also features an adjustable time limit for positive
traction. Another power saving feature is the high speed drive current limit. This feature will automatically control the drive
speed and controller output when it exceeds the pre-set current limit for a specified time and reduce the motor speed, thus
conserving power.
For safety, the machines are equipped with pothole protection and elevation cutback. The pothole protection is employed as
the platform is raised. If the pothole protection does not extend, the drive function will be disabled. When the platform is
raised, the drive function goes into creep mode.
The JLG SMART System™ controller has a built in LED to indicate any faults. The system stores the most recent faults, which
may be accessed for troubleshooting. Optional equipment includes an hourmeter, beacon light, tilt switch (light and/or
alarm), power deck, power deck extension limit, function cutout, and ground alarm. These options may be added later but
must be programmed into the motor controller when installed.
The SMART System™ may be accessed in one of two ways: utilizing a custom designed, hand held analyzer (JLG kit no.
2901443) which will display two lines of information at a time, by scrolling through the program, or a personal computer/lap-
top computer may be used with the system software from JLG (JLG kit no. 2900874), loaded to run under DOS or Windows
3.1 or later. Using the PC/laptop computer will enable you to view the complete screen in each menu.
The instructions in this manual are for using the hand held analyzer.
NOTE: The date code is determined by the first four digits of the controller serial number which is located on the label
attached to the front of the controller.
All SMART™ controllers prior to date code 9808 are JLG part number 1600258.
All SMART™ controllers with date code 9808 and later are JLG part number 1600286. The 1600286 SMART™
controller has built in advanced diagnostic capabilities and the menus and settings vary between the two.
Please refer to the appropriate section in this manual for the correct analyzer use instructions.

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
1-2 – JLG Sizzor – 3120442
To use the hand held analyzer: (1600258 Controller).
1. Connect the four pin end of the cable, supplied with the analyzer, to the top connection of the motor controller 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 connect backwards.
2. Power up the SMART System™ by turning the lower key to the platform position and pulling both emergency stop but-
tons on.
The screen of the analyzer will look like the following:
ASPC MENU:
ACCESS LEVEL 3
Using the RIGHT and LEFT arrow keys, you can scroll throughout the top level menu items, which are:
ACCESS LEVEL
DIAGNOSTICS
PERSONALITIES
MACHINE SETUP
MACHINE DIGITS
Pressing ENTER at any of the above menu items takes you to the menu in that item. In some cases, such as ACCESS
LEVEL, the next level is the parameter or information to be changed. Please note that MACHINE DIGITS can only be viewed
and changed at access level 1. As an example of the next set of menu items, the following are the items under the PERSON-
ALITIES menu:
PLATFORM
GROUND
Under these items are the actual personalities that can be viewed or edited. To see what these personalities are, refer to the
organizational chart in figure 1-1.
The following is an example of how to view and change the DRIVE CREEP personality. This example assumes that the ana-
lyzer has been connected to the machine and the SMART System™ has been powered up.
1. Press the ENTER key when the screen shows the menu ACCESS LEVEL 3.
2. At the CODE prompt, enter 33271. To do this follow the steps below:
a. The flashing cursor should be at the first digit. Use the UP arrow key to increase the number to 3.
b. Use the RIGHT arrow key to scroll to the next digit and repeat step a.
c. Repeat the process until the new code is showing and then press ENTER. If a digit is missed, use the LEFT arrow
key to back up. If you pass the number desired to be entered at a digit, use the DOWN arrow key to decrease the
value.
3. Use the RIGHT arrow key to scroll to the PERSONALITIES menu item and push ENTER.
4. Use the LEFT or RIGHT arrow keys to scroll to the DRIVE CREEP personality.
5. Use the UP and DOWN arrow keys to change the value of the personality. The value is now changed.
6. To view something in DIAGNOSTICS, use the ESC key to back out of the PERSONALITY menu and use the same pro-
cedure to get there.
NOTE: Password 33271 will take you to access level 1, which will permit you to change all machine personality settings. There
are some settings that JLG strongly recommends that you not change, and these settings will be so noted. Changing
these settings may adversely affect the performance of your machine. All parameters accessible using the PC/laptop
computer with the system software are accessible using the analyzer.

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
3120442 – JLG Sizzor – 1-3
Figure 1-1. Organizational Chart - (Machines equipped with 1600258 Controller

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
1-4 – JLG Sizzor – 3120442
Table 1-1. Machine Personality Settings - (Machines equipped with a 1600258 controller).
PERSONALITY MIN MAX
DRIVE-ACCEL 0.5SEC 5.0SEC
DRIVE-DECEL 0 SEC 5.0SEC
LIFT-ACCEL 0.5SEC 5.0SEC
LIFT-DECEL 0.5SEC 1.5SEC
DECK-ACCEL 0.5SEC 5.0SEC
DECK-DECEL 0SEC 5.0SEC
DRIVE-CREEP 1% 25%
LIFT-CREEP 1% 25%
DECK-CREEP 1% 25%
STEER-ONLY-CREEP 1% 35% (seenoteone)
STEER-EXTRA-CREEP 0% 35%
DRIVE-FDWANDREVSPEED 50% 100%-ALLMODELSW/WHITEDRIVEMOTORS
DRIVE-FDWANDREVSPEED 50% 100%-MODEL2033W/EATONDRIVEMOTORS
DRIVE-FDWANDREVSPEED 50% 80%-MODELS1532&1932W/EATONDRIVEMOTORS
LIFT-UP-MAXSPEED 50% 100%
LIFT-DOWN-MAXSPEED 30 100% (seenotes2and3)
DECK-IN-MAXSPEED 0100%
DECK-OUT-MAXSPEED 0100%
GROUNDSPEED-UP 0100%
GROUNDSPEED-DOWN 0100% (seenotes2and3)
GROUNDSPEED-DECKIN 0100%
GROUNDSPEED-DECKOUT 0100%
IDLE-TIME-OUT 0MIN 30MIN

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
3120442 – JLG Sizzor – 1-5
ADDITIONAL FIELD SERVICE SETTINGS
JLG STRONGLY RECOMMENDS THAT THE FOLLOWING SETTINGS NOT BE CHANGED. CHANGING THESE SETTINGS MAY ADVERSELY
AFFECT THE PERFORMANCE OF YOUR MACHINE
NOTE: 1. The steer-only-creep maximum varies, depending on the current machine model. It is not always 35%
NOTE: 2. This adjustment is only for those machines equipped with power LIFT DOWN. To identify machines equipped with
power LIFT DOWN, refer to the Effectivity Page for serial number identification.
NOTE: 3. LIFT DOWN speed is non-adjustable on machines equipped with gravity LIFT DOWN. To Identify machines equipped
with gravity LIFT DOWN, refer to the Effectivity Page for serial number identification.
Table 1-2. Additional Field Service Settings - (Machines Equipped with 1600258 controller).
PERSONALITY MIN MAX
MAX-CURRENT 0A 200A
ELEVATION-CUTBACK 0% 40%
POSITRAC-TIMEOUT 0SEC 255SEC
HIGHDRIVE-CURRENT-LIMIT 50A 200A
HIGHDRIVE-TIME-LIMIT 0SEC 25SEC

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
1-6 – JLG Sizzor – 3120442
Table 1-3. Machine Model Default Settings Chart - (Machines equipped with 1600258 controller)
Adjustment 1532E 1932E 2033E 2046E 2646E 2658E
DRIVEACCELERATION 1.0 1.01.01.01.01.0
DRIVEDECELERATION 0.5 0.50.50.50.50.5
LIFTACCELERATION 1.0 1.0 1.0 1.0 1.0 1.0
LIFTDECELERATION 0.5 0.50.50.50.50.5
DECKEXT./RET.ACCELERATION 1.0 1.0 1.0 1.0 1.0 1.0
DECKEXT./RET.DECELERATION 0.5 0.5 0.5 0.5 0.5 0.5
DRIVECREEPSPEED 88991010
LIFTCREEPSPEED 10 10 15 15 15 15
DECKCREEPSPEED 10 10 10 10 10 10
STEERINGCREEPSPEED 20 20 20 25 25 30
STEER.DR.SPEEDCOMP. 20 20 20 20 20 20
DRIVEFWD&REVSPEEDMAX.(EATON
DRIVEMOTORS) 80 80 100 N/A N/A N/A
(WHITEDRIVEMOTORS) 100 100 100 100 100 100
LIFTUPSPEEDMAXIMUM 80-90 90 100 100 100 100
LIFTDOWNSPEEDMAXIMUM* 60-70* 70-80*80-90* 90-100* 90-100* 90-100*
DECKRETRACTIONSPEEDMAX. 60 60 60 60 60 60
DECKEXTENSIONSPEEDMAX. 100 100 100 100 100 100
ELEVATIONDRIVECUTBACK** 25** 25** 30** 30** 30** 30**
POSITRACHOLDINGTIME** 10** 10** 10** 10** 10** 10**
GROUNDLIFTUPSPEED 75 75 75 80 80 90-100
GROUNDLIFTDOWNSPEED* 60-70* 60-70* 60-70* 60-70* 60-70* 60-70*
GROUNDDECKINSPEED 50 50 50 50 50 50
GROUNDDECKOUTSPEED 50 50 50 50 40 40
HIGHDRIVEOVERCURRENT** 165** 165** 185** 185** 185** 185**
HIGHDRIVETIMEOUT** 5.0** 5.0** 5.0** 5.0** 5.0** 5.0**
MAXIMUMCURRENT** 220** 220** 220** 220** 220** 220**
IDLETIMEOUT 10 10 10 10 10 10

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
3120442 – JLG Sizzor – 1-7
CHANGING THE MACHINE MODEL WILL SET ALL PERSONALITIES BACK TO THE FACTORY DEFAULT SETTINGS. CHECK THE MACHINE
MODEL ADJUSTMENT CHART FOR THE CORRECT SETTINGS FOR EACH MODEL. IF YOUR MACHINE DOES NOT MATCH THE PROPER
SETTINGS FOR EACH MODEL, ADJUST THE SETTINGS AS NECESSARY IN ACCORDANCE WITH THE CHART.
NOTE: * Unless disabled by machine digit #9 (Refer to Table 1-4).
NOTE: * The LIFT DOWN speeds listed in this chart are for those machines equipped with power LIFT DOWN. To identify
machines equipped with power LIFT DOWN, refer to the Effectivity Page for serial number identification. The LIFT
DOWN speeds listed in this chart are the desired speeds for each model. Actual LIFT DOWN speeds may vary from
machine to machine, as each machine is factory-adjusted for maximum smoothness.
NOTE: * LIFT DOWN speed is non-adjustable on machines equipped with gravity LIFT DOWN.
NOTE: ** JLG strongly recommends that these settings not be changed. Changing these settings may adversely affect the per-
formance of your machine.

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
1-8 – JLG Sizzor – 3120442
NOTE: The following information is to be used when working with the MACHINE SETUP menu. When configuring the E Series
scissor lift, the machine configuration must be completed before any personality settings can be changed. Changing the
personality settings first and then changing the model number of the machine configuration will cause the personality
settings to return to default values.
Table 1-4. Machine Configuration Programming Information (Machines equipped with 1600258 controller)
Configuration Digit Number Description Default Setting
Before
Programming
1
(MODELNUMBER) 1 2
3
4
5
6
MODEL1532E
MODEL1932E
MODEL2033E
MODEL2046E
MODEL2646E
MODEL2658E
3
2
(TILTSWITCH) 0
1
2
3
4
Notiltswitchinstalled.
5 tiltswitchforNorthAmericanmachines.—ThisdigitwillallowtheSMARTSys-
tem™toindicatewhenthemachineismorethan5degreesoutoflevelbylightingthe
lightintheplatform.Ifthemachineiselevatedandtilted,theSMARTSystem™will
alsosoundtheplatformalarmcontinuously.Nofunctionsarecutbackorcutout.
2 tiltswitchforEuropeanmachines.—ThisdigitwillallowtheSMARTSystem™to
indicatewhenthemachineismorethan2degreesoutoflevelbylightingthelightin
theplatform.Ifthemachineiselevatedandtilted,theSMARTSystem™willalso
soundtheplatformalarmcontinuously.Nofunctionsarecutbackorcutout.
2 tiltswitchforAustralianmachines.—ThisdigitwillallowtheSMARTSystem™to
indicatewhenthemachineismorethan2degreesoutoflevelbylightingthelightin
theplatform.Ifthemachineiselevatedandtilted,theSMARTSystem™willalso
soundtheplatformalarmcontinuouslyandtheLIFTUPandDRIVEfunctionsarecut
out.
5 tiltswitchforLatinAmericanandJapanesemachines.—Thisdigitwillallowthe
SMARTSystem™toindicatewhenthemachineismorethan5degreesoutoflevelby
lightingthelightintheplatform.Ifthemachineiselevatedandtilted,theSMARTSys-
tem™willalsosoundtheplatformalarmcontinuouslyandtheLIFTUPandDRIVE
functionsarecutout.
0
3
(POWERDECK) 0
1
Nopowerdeckinstalled.
Machineequippedwithpowerdeck.
0

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
3120442 – JLG Sizzor – 1-9
4
(DECKEXT.LIMIT
SWITCH)
0
1
2
Deckextensionlimitswitchnotinstalled.(OptionNumber2mustbeusedifthereisa
powerdeckinstalled.)
CutsoutLIFTDOWNwhendeckisextended.Thisdigitisusedwithrolloutdecksthat
requireadeckextensioncutout.Soundsplatformalarmforonesecondon,onesec-
ondoff,onesecondon,andthreesecondsoffwhileoperatortriestoperformthefunc-
tionthathasbeencutout(providedtheplatformalarmhasbeeninstalled).
CutsoutHIGHDRIVEwhendeckisextendedandbelowelevation.CutsoutDRIVE
whendeckisextendedandaboveelevation.Thisdigitisusedwithapowerdeck.
Soundsplatformalarmforonesecondon,onesecondoff,onesecondon,andthree
secondsoffwhileoperatortriestoperformthefunctionthathasbeencutoutanddur-
ingtheLIFTDOWNfunction(providedtheplatformalarmhasbeeninstalled).
0
5
(FUNCTIONCUTOUT) 0
1
2
Nofunctioncutoutinstalled.
OverloadswitchforFrenchmachines.—Cutsoutallfunctions.Soundsplatform
alarmfortwosecondson,twosecondsoff,whileoperatortriestoperformthefunction
thathasbeencutout(providedtheplatformalarmisinstalled).
OverloadswitchforJapanesemachines.—CutsoutLIFTUPandDRIVE.Sounds
platformalarmfortwosecondson,twosecondsoff,whileoperatortriestoperformthe
functionthathasbeencutout(providedtheplatformalarmisinstalled).
0
6
(GROUNDALARM) 0
1
2
3
Nogroundalarminstalled.
Descentalarm.—SoundswhenLIFTDOWNisactive.
Travelalarm.—SoundswhenDRIVEfunctionisactive.
Motionalarm.—SoundswhenevertheDRIVE,LIFTorDECKfunctionisactive.
0
7
(DRIVECUTOUT) 0
1
Nodrivecutoutswitchinstalled.
CutsoutDRIVEwhendeckiselevatedaboveapredeterminedelevation(varieswith
machinemodel).
0
8
(ARMGUARDSCUTOUT
ORPLATFORMDESCENT
DELAYSYSTEM)
0
1
Noarmguardscutout.
European(CESpecification)machines—allowsLIFTDOWNuntilthedeckislow-
eredtoapproximatelytwometers.HereitwillcutoutLIFTDOWNandsoundtheplat-
formalarmfor1/2secondon,1/2secondoff,andrepeatthisforthreeseconds.After
threeseconds,theoperatormustre-selecttheLIFTfunctionandcontinuetooperate
LIFTDOWN.Ifthewirestothelimitswitchusedtodetectthedeckheightarecutorthe
switchhasfailed,theplatformalarmwillsoundasmentioned.Theoperatorcanre-
selecttheLIFTfunctionandthenLIFTDOWNfortenseconds,atwhichtimeitwillcut
outagainandtheprocessmustberepeated.NOTE:Thealarmandcutoutwillbeacti-
vatediftheplatformisabove2meters,unlesstheyhavebeenactivatedintheprevi-
oustenseconds.
0
Table 1-4. Machine Configuration Programming Information (Machines equipped with 1600258 controller)
Configuration Digit Number Description Default Setting
Before
Programming

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
1-10 – JLG Sizzor – 3120442
NOTE: E Series scissor lifts are equipped with either power lift down or gravity lift down. To identify machines equipped with
power lift or gravity lift down, refer to the Effectivity Page for machine serial number identification.
9
(LIFTDOWN) 0
1
Powerliftdown.(SeeNote)
Gravityliftdown.(SeeNote)
0
Table 1-4. Machine Configuration Programming Information (Machines equipped with 1600258 controller)
Configuration Digit Number Description Default Setting
Before
Programming

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
3120442 – JLG Sizzor – 1-11
Table 1-5. JLG SMART System™ Flash Codes - (Machines equipped with1600258 controller)
Code Description
1-1 Idletime-out
2-1 EMSinputs(bothtogether,orneither).
2-2 Platform(digital)inputs(includeshighdrive>
10seconds).
2-3 Ground(digital)inputs.
2-4 Steering(digital)inputs.
2-5 Cut-outinput(notafaultbutindication).
2-7 Accelerator(analog)input.
2-8 Armguardsorplatformdescentdelaysystem
cut-out.(European[CESpecification]
MachinesOnly)
3-1 Linecontactoropencircuitorwelded.
3-3 Linecontactor(orother)drivershortcircuit
(ortripped).
4-2 Temperaturecutback.
4-4 Batterysupplyvoltageoutofrange.
9-1 Watchdogreset.
9-2 EEpromfault.
9-3 Muxstreamnotbeingupdated.
9-6 PointAshortcircuit.
9-7 PointAopencircuit.
9-8 Motoropencircuit.
9-9 Powercircuitfailure(drivershortcircuit,bat/
cap<15V).

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
1-12 – JLG Sizzor – 3120442
NOTE: Whenever troubleshooting a problem on an E series scissor lift, it may be necessary to use a digital VOM (volt ohm
meter) in addition to the analyzer or the PC/laptop computer. NEVER use a test light when troubleshooting an E series
scissor lift. ALWAYS disconnect the batteries when replacing parts.
Table 1-6. JLG SMART System™ Troubleshooting
TROUBLE PROBABLE CAUSE REMEDY
MachineFunctions
AllMachineFunctionsDoNotOperate EmergencyStopswitchnotactivated.
Joysticknotinneutralposition.(flashcode2-7)
Joystickpotentiometernotcentered.
Idletime-out.(flashcode1-1)
MUXSTREAMNOTBEINGUPDATED.(FLASH
CODE9-3)
Nopowertothemultiplexercardintheplatform.
Platformcablenotconnectedtoplatformboxor
SMARTSystematbase(J2).
Faultymultiplexercard.
BATTERYVOLTAGEOUTOFRANGE.(FLASH
CODE4-4)
Ifbatterychargerispluggedin,voltageofbatteries
maybeabove31Volts
Batteryvoltagetoolow.
LINECONTACTOROPENCIRCUIT.(FLASH
CODE3-1)
Loosewiringconnectionsonlinecontactororat
harnessconnectionJ1
Opencontactonlinecontactor.
FaultywiringatJ1.
Linecontactorwelded.(flashcode3-1)
ActivateEmergencyStopswitchandwaitfor
flashofLED’s.
Releasejoystick,thenselectfunction.
Useanalyzertoverifypotentiometeriscen-
tered.(Axelshouldbe0)Replacejoystick
Selectfunctionagain.
UsevoltmetertoverifypoweronJ4ofthemulti-
plexerboard.
Re-connectcabletoplatformboxorJ2.
Replacemultiplexercard.
CheckvoltagewithVOM.Unplugbattery
charger.
CheckvoltagewithVOM.Pluginbattery
charger.
Checkwireterminationsonlinecontactorand
harnessconnectionatJ1.Tightenconnections
asnecessary.
Cleancorrosionfromlinecontactor.
Replacelinecontactor.
Repairorreplacewiringasnecessary.
Replacelinecontactor.

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
3120442 – JLG Sizzor – 1-13
AllMachineFunctionsDoNotOperate.
(cont.) Linecontactororotherdrivershort-circuitor
tripped.(flashcode3-3)
POINTASHORTCIRCUIT.(FLASHCODE9-6)
Motorleadconnectionsloose.
Faultycontroller.
POINTAOPENCIRCUIT.(FLASHCODE9-7)
Faultycontroller.
Stalledmotor.
Faultymotor.
DisconnectvalveharnessatJ1.Usinganohm
meter,measureresistancebetweenB-and
eachpinoftheconnector,exceptpin10.Each
readingshouldbe1-12megaohms.Ifanyread-
ingisless,replacecontroller.
Checkmotorleadconnections.Tightenconnec-
tionsasnecessary.
Replacecontroller.
Replacecontroller.
Determinecause.Repairorreplacemotoras
necessary.
Replacemotor.
Nodrivefunctionwhenplatformfullylow-
ered.Liftfunctionokay.
CUTOUTINPUT.(FLASHCODE2-5)
Malfunctioninglimitswitch. Useanalyzertoverifylimitswitchinputs.Drive
cutoutandElevationcutoutshouldbeHI.Adjust
orrepairmalfunctioninglimitswitch.
Nodrivefunctionwhenplatformele-
vated.Liftfunctionokay.
CUTOUTINPUT.(FLASHCODE2-5)
Malfunctioninglimitswitch
Platformabovedrivecutoutheight.
Useanalyzertoverifylimitswitchinputs.Pothole
shouldbeHI.Adjustorrepairmalfunctioning
limitswitch.
Lowerplatformbelowdrivecutoutheight.
Machinecannotliftdown.Liftupfunction
okay.
CUTOUTINPUT.(FLASHCODE2-5)
Deckextensionextended. Useanalyzertoverifylimitswitchinputs.Exten-
sionlimitshouldbeHI.Retractdeckextension.
Table 1-6. JLG SMART System™ Troubleshooting
TROUBLE PROBABLE CAUSE REMEDY

SECTION 1 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (1600258 CONTROLLER).
1-14 – JLG Sizzor – 3120442
THIS PAGE WAS LEFT BLANK INTENTIONALLY

SECTION 2 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (CONTROLLER 1600286).
3120442 – JLG Sizzor – 2-1
SECTION 2. JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS
(CONTROLLER 1600286).
INTRODUCTION
The JLG designed SMART System™ is a 24 Volt multiplex motor control unit installed on the electric scissor lift models
1532E, 1932E, 2033E, 2046E, 2646E and 2658E.
The SMART System™ has reduced the need for exposed terminal strips, diodes and trimpots and provides simplicity in
viewing and adjusting the various personality settings for smooth control of: acceleration, deceleration, creep and max-
speed for the lift, drive, steering and optional power deck functions. The function select membrane board, in the upper con-
trol box, also eliminates the need for toggle switches and a separate power enable button as this feature is built into each
function select button on the board itself.
The lift, drive and optional power deck functions are controlled by a joystick, with steering being controlled by a rocker
switch built into the top of the joystick. Drive, lift, and the optional power deck functions are selected by first pushing the
appropriate momentary select buttons on the membrane board and then moving the joystick either in the “A” or “B” direc-
tion. If the joystick is not activated within three seconds of selecting a function, it will be necessary to re-select a function.
High drive and positive traction are used in conjunction with the drive function.
All motor controllers with a date code prior to 9808 have a power saving feature built into the motor controller to shut off
power to the platform controls after ten minutes of idle time. All motor controllers manufactured with a date code after 9808
are featured with an approximate 10 seconds of idle time before the main contactor will open. To reset the system, you sim-
ply select a function or recycle the platform emergency stop button. The motor controller will control current output, as pro-
grammed for smooth operation and maximum cycle time. Ground control speeds for platform lift and the optional power
deck are also programmed into the motor controller. The motor controller also features an adjustable time limit for positive
traction. Another power saving feature is the high speed drive current limit. This feature will automatically control the drive
speed and controller output when it exceeds the pre-set current limit for a specified time and reduce the motor speed, thus
conserving power.
For safety, the machines are equipped with pothole protection and elevation cutback. The pothole protection is employed as
the platform is raised. If the pothole protection does not extend, the drive function will be disabled. When the platform is
raised, the drive function goes into creep mode.
The JLG SMART System™ controller has a built in LED to indicate any faults. The system stores recent faults which may be
accessed for troubleshooting. Optional equipment includes an hourmeter, beacon light, tilt switch (light and/or alarm), power
deck, power deck extension limit, function cutout, and ground alarm. These options may be added later but must be pro-
grammed into the motor controller when installed.
The SMART System™ may only be accessed utilizing a custom designed, hand held analyzer (JLG kit no. 2901443) which
will display two lines of information at a time, by scrolling through the program.
The instructions in this manual are for using the hand held analyzer.
NOTE: The date code is determined by the first four digits of the controller serial number which is located on the label
attached to the front of the controller.
All SMART™ controllers prior to date code 9808 are JLG part number 1600258.
All SMART™ controllers with date code 9808 and later are JLG part number 1600286. The 1600286 SMART™
controller has built in advanced diagnostic capabilities and the menus and settings vary between the two.
Please refer to the appropriate section in this manual for the correct analyzer use instructions.
updated: 11/98

SECTION 2 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (CONTROLLER 1600286).
2-2 – JLG Sizzor – 3120442
JLG SMART System™Analyzer Instructions for Controller Number1600286
NOTE: The part number of the controller is located on the controller decal.
• To connect the hand held analyzer for ALL 1600286 controllers:
1. Connect the four pin end of the cable supplied with the analyzer, to the top connection of the motor controller and con-
nect 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 SMART System™ by turning the lower key to the platform position and pulling both emergency stop but-
tons on.
• Using the analyzer with ALL 1600286 controllers:
With the machine power on and the analyzer connected properly, the analyzer will display the following:
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed
menu item, press ENTER. To cancel a selected menu item, press ESC; then you will be able to scroll using the right and left
arrow keys to select a different menu item.
The top level menus are as follows:
HELP
DIAGNOSTICS
RUN SYSTEMS TEST (NOTE:Ensure machine is fully lowered before running systems test)
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (level 1 only)
If you press ENTER, at the HELP:PRESS ENTER display, and a fault is present during power up, the analyzer display will
scroll the fault across the screen. If there was no fault detected during power up, the display will read: HELP: EVERYTHING
OK
If ENTER is pressed again, the display moves to the following display:
LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the current fault, if any are present. You may scroll through the fault logs to view what
the last ten faults were. Use the right and left arrow keys to scroll through the fault logs. To return to the beginning, press
ESC two times.
When a top level menu is selected, a new set of menu items may be offered; for example:
PLATFORM
GROUND
SYSTEMS
DATA LOG
VERSIONS
DRIVE

SECTION 2 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (CONTROLLER 1600286).
3120442 – JLG Sizzor – 2-3
LIFT
STEER
GROUND MODE
MACHINE
Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu. In
some cases, such as DRIVE, the next level is the parameter or information to be changed. Refer to the flow chart for what
menus are available within the top level menus. You may only view the personality settings for selected menus while in
access level 3. Remember, you may always cancel a selected menu item by pressing the ESC key.
• Changing the access level of the hand held analyzer: (ALL 1600286 controllers)
When the analyzer is first connected, you will be in access level 3 which enables you to only view most configuration settings
which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be acci-
dentally 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 3
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 password was entered correctly:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.
• Adjusting configuration using the hand held analyzer on ALL 1600286 controllers:
Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its
value, for example:
PERSONALITIES:
DRIVE ACCEL 1.0s
There will be a minimum and maximum for the value to ensure efficient operation. The value will not increase if the UP arrow
is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the min-
imum value for any particular personality. If the value does not change when pressing the up and down arrows, check the
access level to ensure you are at access level 1.
When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example:
GROUND ALARM:
2=DRIVE
The effect of the machine digit value is displayed along with its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to sound when driving. There are certain settings allowed to install
optional features or select the machine model.

SECTION 2 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (CONTROLLER 1600286).
2-4 – JLG Sizzor – 3120442
When selecting the machine model to match the size of the machine, the personality settings will all default to the factory
recommended settings. Note: Refer to the appropriate Machine Personality Settings Table, and the Machine Setup
Table in the JLG Service Manual for the recommended factory settings. Refer to the JLG part number of the control-
ler, printed on the front label, to select the correct table in the manual.
NOTE: Password 33271 will give you access to level 1, which will permit you to change all machine personality settings. There
are some settings that JLG strongly recommends that you do not change. These settings are so noted below:
MAX CURRENT
ELEVATION CUTBACK
POSITRAC TIMEOUT
HIGH DRIVE CURRENT LIMIT
HIGH DRIVE TIME LIMIT
CALIBRATION
CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON THE MACHINE, ELECTRICAL SILICONE GREASE, JLG PART NUMBER
0100076 OR 7016397, MUST BE APPLIED TO THE BACK OF THE CONTROLLER.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE
UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/
ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY
SATURATION.

SECTION 2 - JLG SMART SYSTEM ™ ANALYZER KIT INSTRUCTIONS (CONTROLLER 1600286).
3120442 – JLG Sizzor – 2-5
Figure 2-1. Organizational Chart - (Machines equipped with 1600286 controller)