Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell; Checking/Changing The Battery Charger Algorithm - JLG E450A Service And Maintenance Manual

SECTION 3 - CHASSIS & TURNTABLE
3. Confirm that dirt or mud is not blocking the cooling fins
of the charger. Clean the charger. Rinse the charger with
a low pressure hose if required. Do no use high pressure.
Do not us a pressure washer.
[6 Flashes] - Over Load/Over Temperature
This fault indicates that the batteries will not accept charge
current, or an internal fault has been detected in the char-
ger. This fault will nearly always be set within the first 30
seconds of operation. If it occurs after the charger has
started charging normally, be sure to make a note of it.
1. Remove excessive AC loads from inverter if installed.
2. Try to clear the fault by unplugging the AC, waiting 30
seconds and reconnecting the ac power.
3. Check all battery connections. Look for a high resistance
connection. The most likely reason for this fault is a fault
in the battery such as a bad battery connection, an open
cell, or insufficient water.
4. This fault will occur if an internal fuse inside the charger
blows. If the green wire is shorted to ground even
momentarily, this fuse will blow. To check the fuse, mea-
sure with an ohmmeter between the green and red
wires with the AC disconnected. If a short circuit is not
measured, the fuse has blown. Return unit to a service
depot to have this fuse replaced.
5. If this fault occurs after battery charging has started,
confirm that AC power was not interrupted and that all
battery connections are good.
6. If all battery connections are good, an internal fault has
been detected and the charger must be brought to a
qualified service depot.
Excessive Battery Watering Requirements or
Strong Sulphur (Rotten Egg) Smell
These symptoms indicate over-charging or high battery
temperature. These symptoms are unlikely to be caused by
too high a charge current since the maximum charge cur-
rent of the charger will be small compared to even a mod-
erately sized battery pack. The most likely cause for this
problem is incorrect charge algorithm setting and/or high
ambient temperatures.
1. Confirm that the battery pack is not too small - usually >
50Ah.
2. Confirm that the nominal battery voltage matches the
charger output voltage.
3. Confirm the correct battery charge algorithm. If the bat-
tery pack is new, the algorithm will need to be changed
if the pack is not the same as the old one. for instruc-
tions on how to determine and change the battery
charge algorithm see the following sub-section.
3-62
4. If the output voltage of the charger seems excessive,
return the charger for service. Contact JLG to get the
expected battery voltage settings for the charger in
question. Be sure to have the charger's serial number
and charge algorithm setting available when calling.

Checking/Changing the Battery Charger Algorithm

The charger is pre-loaded with programming algorithms
for the specific batteries detailed in Table 3-4, Battery Algo-
rithms.
NOTE: Contact JLG if your specific battery model is not listed.
Each time AC power is applied with the battery pack not
connected, the charger enters an algorithm select/display
mode for approximately 11 seconds. During this time, the
current Algorithm # is indicated on the Yellow Charging
LED. A single digit Algorithm # is indicated by the number
of blinks separated by a pause. A two digit Algorithm # is
indicated by the number of blinks for the first digit fol-
lowed by a short pause, then the number of blinks for the
second digit followed by a longer pause.
To check / change the charging algorithm:
1. Disconnect the charger positive connector from the bat-
tery pack. Apply AC power and after the LED test, the
Algorithm # will display for 11 seconds.
2. To change the algorithm, touch the connector to the
battery's positive terminal for 3 seconds during the 11
second display period and then remove. The Algorithm
# will advance after 3 seconds. Repeat this procedure
until the desired Algorithm # is displayed. A 30 second
timeout is extended for every increment. Incrementing
beyond the last Algorithm will recycle back to the first
Algorithm. When the desired Algorithm is displayed,
touch the charger connector to the battery positive ter-
minal until the output relay makes a clicking noise
(approx. 10 seconds). The algorithm is now in the per-
manent memory.
3. Remove the AC power from the charger and reconnect
the charger's positive connector to the battery. It is rec-
ommended to check a newly changed algorithm by
repeating the above steps 1 and 3.
Table 3-4. Battery Algorithms
Algorithm # JLG PN
173 1001114782
173 0400055
Proper
Battery Type Algorithm
Setting
DISCOVER EV 305A-A 43
US BATTERY L16 173
3121714