Battery Charger/Inverter Troubleshooting - JLG 1930ES Service Maintenance Manual

Battery Charger/Inverter Troubleshooting

The Fault LED Flash Codes are the same as the Battery
Charger (see Battery Charger Troubleshooting on pages
3-29 and 3-30).
For further specification and troubleshooting information
refer to the manufacturers' Charger/Inverter Owner's
Guide shipped with the machine. Publication - RM1024-
JLG - Part # 3128406.
Use the information below to supplement the information
in the Inverter/Charger manual. First, go through the trou-
bleshooting in the Owner's Guide (JLG part number
3128406), then use the procedures below. For control of
the Inverter/Charger there is an 8 position connector on a
cable entering the case of the Inverter/Charger. Looking at
the pins of the connector, terminals are numbered clock-
wise starting with number 1 nearest the notch. Terminal 8
is in the center.
No charge voltage:
1. Disconnect control cable from Inverter/charger.
2. Turn on machine.
3. Inverter/charger control cable 8 position connector
socket 1 should have Vbatt present. If it is not, check
charger interlock connector, 2 position, socket 1. If
voltage is present there replace the Inverter/Charger
data interface harness. If Vbatt is not present at the 2
position connector socket 1, check the circuit
through the chassis harness back to Ground Mod-
ule terminal J1-19.
Loads will not start when there is no external AC/
Inverter will not produce AC power:
1. Check that Inverter/Charger switch is in ON position.
2. Disconnect control cable from the Inverter/Charger.
3. Turn on machine.
4. Inverter/Charger control cable socket 2 should have
Vbatt present when the switch is ON. If not check
that there is Vbatt on the switch Yellow/Red wire.
Vbatt signal originates from Ground module pin J1-
19 then goes to harness Interlock connector termi-
nal 1 (Yellow/Red wire), then to switch.
LED(s) suspected to be bad:
1. Disconnect Inverter/Charger control cable from the
charger (8 position connector) and the 6 position
connector at the chassis harness. There should be
continuity between the following:
a. 8 pos. terminal 3 to 6 pos. terminal 3
b. 8 pos. terminal 4 to 6 pos. terminal 5
c. 8 pos. terminal 5 to 6 pos. terminal 4
d. 8 pos. terminal 6 to 6 pos. terminal 6
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SECTION 3 - CHASSIS & SCISSOR ARMS
2. Disconnect Inverter/Charger control cable at the 6
position connector and the chassis harness at the 4
position connector at the Ground Box. There should
be continuity between the following:
a. 6 pos. terminal 3 to 4 pos. terminal 1
b. 6 pos. terminal 4 to 4 pos. terminal 3
c. 6 pos. terminal 5 to 4 pos. terminal 2
d. 6 pos. terminal 6 to 4 pos. terminal 4
3. If wiring is found to be good, the LED printed circuit
card is likely to be bad.
Interlock Cable suspected to be bad or vehicle thinks
charging is in progress, but it is not:
1. Disconnect Interlock (2 position) connector on the
Inverter/Charger control cable.
2. Turn on machine.
3. There should be Vbatt present on the Interlock con-
nector socket 1.
4. Turn off machine.
5. Disconnect Inverter/Charger control cable at the
charger.
6. Inverter/Charger connector (8 position) pin 6 should
have continuity to Interlock connector pin 2 and then
to ground module socket J1-29.
Ground Module powered while key is off or similar
behavior:
This condition can be caused by various ground module
outputs getting shorted to battery. If not done already,
cycle power and check for fault codes. If no fault codes,
perform the following:
1. Disconnect the Inverter/Charger control cable at the
8 position connector and the 2 position Interlock
connector.
2. Set digital multimeter to diode check or continuity
check to check diode in Inverter/Charger control
harness. If the meter does not have these features a
low range Ohm scale (20 Ohms for example) will
work.
3. Place red lead on 8 position connector pin 1. Place
black lead on Interlock connector pin 1.
4. Meter should read an open. Swap leads. Meter
should read a short. If either condition is not good,
replace Inverter/Charger control cable.
– JLG Lift – 3-49