JLG 3246ES Service Manual - Manual (Page 81)

SECTION 3 - CHASSIS & SCISSOR ARMS
3121166 – JLG Lift – 3-45
Battery Charger Troubleshooting
No Lights at all
No Lights at all indicate that AC power to the charger is
not connected or that the AC voltage is too low. It could
also indicate an internal failure in the charger.
1. Check the connections to AC power. Check for AC
voltage between 90 and 260 VAC at the charger.
2. If the AC voltage is verified to be correct at the
connection to the charger, and the charger still
displays no lights at all, return the charger for ser-
vice.
FAULT LED Flashing
The Fault LED flashes to indicate the micro-controller
inside the battery charger has detected a fault. The fault
detected is indicated by the number of flashes. Count
the number of flashes to determine the fault.
With any battery system, the most common problem
will be a faulty battery connection. Because of the high
likelihood of a battery connection problem, it is always
worthwhile to confirm that all connections are good
before checking for any other problems.
[1 Flash] - High Battery Voltage
1. Indicates a high battery voltage. Check that the
battery charger voltage is consistent with the bat-
tery pack voltage. The first two digits of the four
digit model name indicate the battery voltage the
charger supports.
2. Check for wiring errors.
3. This fault will automatically clear and the charger
will restart charging when this problem is
removed.
4. High battery voltage could also occur if there is
another source charging the battery. Disconnect
any other sources during charging.
5. If this problem does not clear after the battery
voltage is confirmed to be less than 2.4V per cell,
return the charger for service.
[2 Flashes] - Low Battery Voltage
1. Indicates either a battery failure, no battery con-
nected, or a lower than expected battery voltage.
Check the battery and battery connections.
2. Check the nominal battery voltage. The first two
digits of the four digit model name indicate the
battery voltage the charger supports. Confirm that
a nominal battery voltage is the same as the char-
ger voltage.
3. This fault will clear automatically when the low
battery voltage problem is rectified.
4. If this problem does not clear after the battery
voltage is confirmed to be higher than 1.0V per
cell and all connections are good, return the char-
ger for service.
[3 Flashes] - Charge Time-out
Indicates the battery failed to charge within the allowed
time. This could occur if the battery is of larger capacity
than the algorithm is intended for. In unusual cases it
could mean charger output is reduced due to high
ambient temperature. It can also occur if the battery is
damaged, old, or in poor condition.
1. Check the battery for damage such as shorted cells
and insufficient water. Try the charger on a good
battery.
2. If the same fault occurs on a good battery, check
the connections on the battery and connection to
AC, and the AC voltage itself.
3. Confirm that the nominal battery pack voltage is
the same as the battery charger voltage.
4. This fault must be cleared manually by unplugging
the AC, waiting 30 seconds and reconnecting the
AC power.
5. If a charger displays this fault on a battery pack,
and the pack is of questionable status, reset the
charger by disconnecting AC for 30 seconds, and
then reconnect the AC to start a new charge cycle.
After a few charge cycles, this problem could stop
occurring as the pack "recovers."
[4 Flashes] - Check Battery
This fault indicates the battery pack could not be trickle
charged up to the minimum level required for the nor-
mal charge cycle to be started.
1. Check that none of the battery pack connections
between modules are reversed or incorrectly con-
nected.
2. Check that one or more cells in the battery are no
shorted.
3. Confirm that the nominal battery pack voltage is
the same as the battery charger voltage.
4. Try the charger on a good battery.
5. If this fault occurs, the battery is likely in poor con-
dition. Try to recover the pack with a charger that
can charge the individual cells - such as an auto-
motive charger. Be sure to set this charger to the
appropriate voltage - 6V per 6V battery, 12V per
12V string/battery.