JLG Industries, Inc.

JLG Drive
McConnellsburg, PA 17233-9502
Telephone (717) 485-5161
Fax 717-485-6417

INSTRUCTION MANUAL
ELECTRIC DRIVE

How to use the

CONTROL MODULE CALIBRATOR
P/N 7013305
(3 & 4 Button Models)
15 April 1992 3120363
Revised 15 March 1994
 INTRODUCTION

The control module is truly the heart of the electrical and hydraulic system on the Electric Drive machines.

The Calibrator allows you to access systems information, check component operation, and adjust the
speed or percentages of all functions to meet the required spec. It should be used only by properly trained
and qualified personnel.

This Instruction Manual will identify and explain the function checks as they occur, in sequence, in the
control module memory bank.

All Calibrators (P/N 7013305) shipped prior to March 1994 contained 3 buttons. Calibrators shipped after
this date will be equipped with 4 buttons and will directly replace the 3 button models. The 4 button
calibrator will also maintain the same JLG P/N.

Both Calibrators will perform all the same functions with exception to changing software settings, which
the 4 button calibrator must be used.

Software settings must not be changed. The only time this adjustment will be required is when replacing
the control module, see chart for set-up procedures.

Control Module Settings Chart

JLG MODELS LIFTS SIZZORS

SETTINGS 30 35/N35 40/N40 45 30 40 3369 3969
ELECT ELECT ELECT ELECT HA HAE ELECT ELECT
* SOFTWARE 101 104 104 105 (See Note) (See Note) 102 102
* MAX. CURRENT 270 400 400 600 270 400 400 400
ACC. DELAY 2.0 1.5 1.5 1.5 2.0 1.5 1.5 1.5
DEC. DELAY .5 .5 .5 .5 .5 .5 .5 .5
* OFF LEVEL CREEP 0 0 0 0 0 0 0 0
* MAX. SPEED 70 100 100 100 70 100 85 85

* CUT BACK 1 ELEV. 10 13 13 13 10 13 13 10

* CUT BACK 2 SLOPE 50 60 60 60 50 60 60 60
PUMP ACC. 3 3 3 3 3 3 3 3

PUMP THRESHOLD 10 10 10 10 10 10 20 20
o CONTROL MODULE
7013310 7013310 7013310 7013311
7013310 7013310
7013310 7013310
PART NUMBER (See Note) (See Note)

* These settings must be to exact factory specifications. Any deviations must be

factory approved.

o Replacement control modules are available blank or pre calibrated per model. Blank
control modules must be calibrated at installation per this procedure using a
4-button calibrator. Pre-calibrated control modules are shipped ready for use,
specify machine model when ordering.

Note
When Control Module with a date code of 01 94 or later is used on a 30HA or 40HAE, follow
the 30 electric software setting procedure for 30HA and 40 electric for 40HAE. The date code
is the first four digits of the serial number. (01 = Month; 94 = Year)
 PARAMETER ADJUSTMENTS
First turn on power and then depress footswitch.
Your foot must remain on the foot switch throughout the cycle sequence. If you remove your foot from
the foot switch you will cancel the sequence and you will need to start again from the beginning. Never
block the foot switch in the activated position.
The first reading on display will be cycle time - this shows the minutes, hours and hundreds of hours that
this machine has been used. First display is minutes, next press (-) or dn button for hours, then press (+)
or up button for hundreds of hours.
Max. Current
Press select button and #1 LED comes on and digital read out displays max. current (See Chart). This
is the amount of available amps to drive motors for driving and plug braking (plug braking is the reversing
of drive motors to maintain speed selected by drive controller). The maps should always be adjusted to
specs. which is maximum. This is very important for safety reasons.
Acc. Delay
Press select button again and #2 LED comes on. This is acceleration delay. This is how long it takes the
drive motors to go from 0 to maximum speed. Similar to “Ramp” on hand controllers. This delay can be
set from 1 to 3 seconds, (See Chart) for normal settings. By pressing the plus or up button we can increase
the delay time in tenths of sec. To lower the time, press the minus or down button.
Dec. Delay
Press select button again and #3 LED comes on. This is just the opposite of #2 the slow down of drive
motors from maximum speed to 0. Similar to ramp effect to stop. See Chart for normal settings.
Off Level Creep
Press select button again and #4 LED comes on.
Max. Speed
Press select button again and #5 LED Max. Speed comes on. This regulates the travel speed of the
machine. This can be set from 0 to 100% of maximum. See Chart for normal setting, which is equal to
approx. 4 mph. This is the standard speed for this machine and must not be changed.
Cut Back 1 Elev.
Press select button again and #6 LED comes on, this slows down travel speeds from 5% to 20% of normal
speed when boom is above horizontal position. See Chart for normal settings. By pressing the plus or
up button the percent of slow down will be increased. The machine will go slower than normal. By pressing
the minus or down button the percent of slow down will be decreased and the machine will go faster.
Cut Back 2 Slope
Press select button again and #7 LED comes on, this slows down travel speeds from 5% to 60% of normal
speed when chassis is out of level and tilt indicator is activated. See Chart for normal setting.
Pump Acc.
Press select button again and #8 LED comes on, this soft starts pump motor - a ramp effect to soften the
beginning of Lift and Swing functions only, as drive is total electric. The adjustment is from a .5 sec. to 5
sec. See Chart for normal setting.
Pump Threshold
Press select button again and #9 LED comes on, this sets pump creep speed. In other words, how fast
the pump and motor combination runs. The function speed control on the platform control console must
be set at slowest position when checking or setting this adjustment. Range of setting is 0% to 30% of
maximum. See Chart for normal setting.

All of the above functions can be adjusted within the parameters set up for that particular function by
pressing the plus (+) or minus (-) buttons.
This ends the area on the Calibrator where adjustments can be made.

Page 2
The next four modes will display present and past conditions of batteries and electric control module.
This information cannot, I repeat cannot, be removed by anyone other than the manufacture of the electric
control module.
Press select button again and present battery condition in volts is displayed. Pressing the plus or up
button displays maximum volts that has ever been in the batteries. Pressing the minus or down button
displays the lowest voltage ever seen by the batteries.
Press select button again and motor volts can be displayed when hand controller is activated. The amount
of volts will vary with grade conditions.
Press select button again and motor maps can be displayed when hand controller is activated. The
amount of maps will vary with grade conditions.
Press select button again for temp. This is the temp of the electric control module. The first display is
present temp. in degrees celsius. Press plus or up button to display highest temp. ever recorded by
electric control module. Press minus or down to display lowest temp. ever recorded be electric control
module.
Press select button again for test mode. By pressing the up or down button you can access in any order
you wish, any of the test functions.
Press up button to select drive pot output a zero will be displayed. Activate drive hand control to obtain
read out. Zero being neutral or center position and 100 being maximum. Pot adjustment can be checked
by forward or reverse of controller. Use caution if drive wheels are not jacked up off of floor or ground.
Press plus button to check forward contactor. Display will show 1 OP for open until drive controller is
activated in the forward position. Then display will show 1 CL for closed.
Press plus button to check reverse contactor. Display will show 2 OP for open until drive controller is
activated in the reverse position. This display will show 2 CL for closed.
Press plus button for tach input (Range 0 % to 100%). This display will show if their is any difference
between forward and reverse speed. Raise drive wheels off ground or floor and function drive hand
controller in both directions, note reading in each direction.
Press plus button for elevation switch. The display will show 4 CL or closed. Activate boom up until above
horizontal is reached, display will show 4 OP for open.
Press plus button for tilt sw. The display will show 5 CL for closed. Drive machine on slope until chassis
tilt indicator lights. Display will show 5 OP for open. You may also have someone push tilt switch to one
side and hold while reading is being checked.
Press plus button again for change over contactor. Display will show 6 OP for open until lift or swing
functions are activated, then 6 CL for closed will be displayed.
Press plus button again for direction last operated. This test function is used by the manufacture of the
control module.
The Calibrator is a very quick and easy way to troubleshoot problems and adjust the functions.
From a safety standpoint, again we must stress that only trained and qualified personnel have access to
the Calibrator.

Page 3
 HOW TO USE THE CONTROL MODULE CALIBRATOR
(3 & 4 BUTTON MODELS)
Plug the calibrator into the electric control module and get into the platform.

Be careful when raising boom while holding Calibrator as Calibrator is plugged into control module.

The extended cord on the calibrator enables you to perform these checks while standing in the platform.

All applicable safety practices must be observed.

Persons not directly involved in the test procedures must be kept clear of the operational area.

Test procedures to check and adjust drive control functions may be conducted with machine in motion
if work site conditions permit.

When travel space is limited, as in a service shop location, raise the drive wheels off the ground and block
the chassis frame securely. Again, safe work practices are a must.

If you wish to check a specific function, you may do so by holding down the select button. The calibrator
will cycle thru the function modes. Then release the select button when the specific functions mode you
want to check appears.
SOFTWARE SETTINGS
(4 - Button Calibrator Required)
Note
This adjustment not required for normal service. Required only for set-up when replacing control
module or panel. Not applicable to models 30 HA & 40HAE unless control module or panel is replaced.

1. Turn power on.

2. Depress calibrate button and hold for 5 seconds. Current software will be displayed. Example:
101

3. Press select button and software revision will be displayed. Example: 06

4. Press select again and the number 1 will appear in the left of this display. This indicates the first
digit of the password. Another digit will appear in the right of the display.

5. Enter password 73461829 using + and/or - key change right digit to first digit of password
(example) with number 1 in left side of display key + or - until number 7 appears on right side of
display. Press select and number 2 will appear on left side of display, enter second digit of
password. Continue until all 8 digits of password are entered.

6. Press select button. If password was entered correctly _ _ _ will appear on display. If a number
appears recycle power and start again.

7. If _ _ _ appeared use + and - keys to select appropriate software. Example: 101

8. Press calibrate button and hold for 5 seconds. Cal will appear on display.

9. Recycle power and repeat step 2 to verify software selection.

Page 1
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia) JLG Industries (UK)
P.O. Box 5119 Unit 12, Southside
11 Bolwarra Road Bredbury Park Industrial Estate
Port Macquarie Bredbury
N.S.W. 2444 Stockport
Australia SK6 2sP
Phone: (61) 2 65 811111 England
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Latino Americana Ltda. JLG Europe B.V.
Rua Eng. Carlos Stevenson, Jupiterstraat 234
80-Suite 71 2132 HJ Foofddorp
13092-310 Campinas-SP The Netherlands
Brazil Phone: (31) 23 565 5665
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd.
Kilmartin Place, Unit 1, 24 Industrial Complex
Tannochside Park Herman Street
Uddingston G71 5PH Meadowdale
Scotland Germiston
Phone: (44) 1 698 811005 South Africa
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334
Fax: (27) 11 453 1342
JLG Deutschland GmbH JLG Industries (Italia)
Max Planck Strasse 21 Via Po. 22
D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Bei Bremen Italy
Germany Phone: (39) 02 9359 5210
Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Fax: (49) 421 693 5035
JLG Industries (Norge AS) JLG Polska
Sofeimyrveien 12 UI. Krolewska
N-1412 Sofienyr 00-060 Warsawa
Norway Poland
Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Plataformas Elevadoras JLG Industries (Sweden)
JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 175 27 Jarfalla
08755Castellbisbal Sweden
Spain Phone: (46) 8 506 59500
Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (34) 93 77 11762