JLG X390AJ-X14J Supplement Manual
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JLG X390AJ-X14J Supplement Manual

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Supplement Manual
Models
X390AJ-X14J
X550AJ-X19J
X700AJ-X23J
X370AJ-X13JP
X430AJ-X15JP
X500AJ-X17JP
X600AJ-X20JP
X770AJ-X26JP
X1000AJ-X33JP
*See inside cover for serial break
information
31215460
October 14, 2019

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Deo
May 29, 2025

How to operate

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1 comments:
Mr. Anderson
May 29, 2025

To operate the JLG X390AJ-X14J, follow these key steps based on the provided information:

1. Battery Power On: Turn ON the 12V lead-acid battery switch. This activates the Battery Management System (BMS) through ECM1-2.

2. BMS Check: Ensure there are no faults. If clear, the BMS receives power from the Lithium-ion battery pack.

3. Battery Levels and Speed Control:
- If battery level is below 4%, the machine operates at ultra-low speed (only for 3rd Gen models).
- If battery level is below 0%, connect the plugs to proceed.

4. Emergency Electric Motor Override (only in emergencies):
- Turn OFF the battery switch.
- Bridge the designated electrical points.
- Turn ON the battery switch.
- As soon as the operator reaches the ground, remove the jumper bridge.
- Note: Safety controls are not active during override.

5. Safety Precautions:
- If battery compartment temperature is high, open it carefully and wait until it cools to ambient temperature.
- Do not open the compartment if temperature is too high due to explosion or hazardous exposure risk.
- Wear appropriate protective equipment.
- Use Class D fire extinguisher in case of fire.

These steps ensure correct and safe operation of the JLG X390AJ-X14J.

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Summary of Contents for JLG X390AJ-X14J

  • Page 1 Supplement Manual Models X390AJ-X14J X550AJ-X19J X700AJ-X23J X370AJ-X13JP X430AJ-X15JP X500AJ-X17JP X600AJ-X20JP X770AJ-X26JP X1000AJ-X33JP *See inside cover for serial break information 31215460 October 14, 2019...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...
  • Page 3 Models 48V Gen1 48V Gen 2 72V Gen1 72V Gen 2 X390AJ-X14J Prior to SN SN 170000350 C170000323 to Present X550AJ-X19J Prior to SN SN C170000332 C170000319 to Present X700AJ-X23J Prior to SN SN C170000352 C170000340 to Present X370AJ-X13JP X430AJ-X15JP...
  • Page 4 Lithium ION system, which is one of the power system The CCB with dual power configuration, Gasoline/Diesel configurations on JLG Compact Crawler Booms (CCB). and electrical motor, are coupled with two tandem pumps, while those with the Lithium ION, have only one...
  • Page 5 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue A - October 14, 2019 31215460...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL................. . A-1 SECTION 1 - SPECIFICATIONS CAPACITIES .
  • Page 7 TABLE OF CONTENTS SECTION 3 - TROUBLESHOOTING AND FAULT CODES FAULT CODES ................3-1 BATTERY SYSTEM TROUBLESHOOTING (1ST &...
  • Page 8 LIST OF FIGURES 1-1. 48V Pack Upper Section (1st Generation)............1-2 1-2.
  • Page 9 LIST OF TABLES Lithium Systems..................1-1 Cell Features .

  • Page 10: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS CAPACITIES Table 1-1. Lithium Systems Model Battery Pack Machine Arrangement X390AJ-X14J X500AJ-X17JP 48V - 15 Cells X550AJ-X19J X700AJ-X23J 72V - 22 Cells X600AJ-X20JP 72V - 22 Cells Refer inside cover for serial break information...

  • Page 11: Battery Pack Configuration Layout

    SECTION 1 - SPECIFICATIONS BATTERY PACK CONFIGURATION LAYOUT MAF11320 Figure 1-1. 48V Pack Upper Section (1st Generation) MAF11330 Figure 1-3. 72V Pack Upper Section (1st Generation) MAF11340 Figure 1-2. 48V Pack Upper Section (2nd Generation) MAF11350 Figure 1-4. 72V/83V Pack Upper Section (2nd Generation) 31215460...

  • Page 12: Battery Pack Component Identification

    SECTION 1 - SPECIFICATIONS MAF11360 MAF11370 Figure 1-5. 38V Pack Upper Section (3rd Generation) Figure 1-6. 76V Pack Upper Section (3rd Generation) Table 1-3. Battery Pack Component Identification Battery Charger Battery Management System CAN Bridge Box CAN BUS Lines Bridge (X23J - X700AJ only) DC-DC Electronic Current Transformer, from 38/48/72/76/83 Volt DC to 13.5 Volt F No...
  • Page 13 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 14: Service Procedure

    SECTION 2 - SERVICE PROCEDURE SECTION 2. SERVICE PROCEDURE 12V DC POWER DISTRIBUTION The 12V Lead-acid battery provides the power to the machine electronic control module (ECM) in the machine The 12V power distribution system provides the electrical until the engine starts. Once the engine starts, the engine power required to operate the machine’s Electronic con- driven generator, provides 13.5V electrical power for the trol modules (ECM), solenoid valves and lights.

  • Page 15: Operation Of The Power Pack Components

    SECTION 2 - SERVICE PROCEDURE OPERATION OF THE POWER PACK COMPONENTS LEAD-ACID Lithium Battery Charger AC-DC Lithium Battery Pack MAF11410 The BMS regulates the amount of current coming IN Theory of Operation (recharge) and coming OUT (to electrical motor or the DC- Switching ON the dual contact key switch (C) directs indi- DC transformer).

  • Page 16: Battery Management System (Bms)

    SECTION 2 - SERVICE PROCEDURE BATTERY MANAGEMENT SYSTEM (BMS) 48V/72V Systems with 1st Generation BMS The Battery Management System (BMS) is the electronic The 1st generation BMS is the same for 48V and 72V sys- device which constantly monitors the state of the LiFePO4 tems, but they are not interchangeable.

  • Page 17: Bms Connectors (1St Generation Bms)

    SECTION 2 - SERVICE PROCEDURE BMS Connectors (1st Generation BMS) MAF11440 Table 2-1. 1st Generation BMS Connectors CAN BUS Module Socket Current Sensor Socket (LEM) Power and Contactor Socket Temperature Sensor Socket Voltage Cells Measurements Socket Resistance to Discharge the Cells during the Equalization Phase 31215460...

  • Page 18: 48V Systems With 2Nd Generation Bms

    SECTION 2 - SERVICE PROCEDURE 48V Systems with 2nd Generation BMS 72V/83V with 2nd Generation BMS The 72V and 83V BMS is composed of two electronic cards, The 2nd Generation BMS can be arranged with one or two positioned one above the other in the same case, BMS A electronic cards.

  • Page 19: Bms Connectors (2Nd Generation Bms)

    SECTION 2 - SERVICE PROCEDURE BMS Connectors (2nd Generation BMS) 48 Volt Battery Pack MAF11490 Table 2-3. 2nd Generation BMS Connectors J1, J2, J3 Temperature Sensor Sockets Voltage cells Measurements Socket Resistance to discharge the cells during the Equalization phase Internal contactor and fans Current sensor socket (LEM) BMS feed...

  • Page 20: Temperature Sensor Test - 2Nd Generation

    SECTION 2 - SERVICE PROCEDURE Temperature Sensor Test - 2nd Generation 38V/76V with 3rd Generation BMS The 3rd Generation BMS can be arranged with one or two electronic cards. The 38V and 76V BMS for 3rd gen- eration are interchangeable with software update. The 3rd Generation BMS manages all the functions as described in the 1st Generation BMS.

  • Page 21: Bms Connectors (3Rd Generation Bms)

    SECTION 2 - SERVICE PROCEDURE BMS Connectors (3rd Generation BMS) 38 Volt Battery Pack 76 Volt Battery Pack BMS Arrangement MAF12760 Figure 2-7. 3rd Generation BMS Connectors Table 2-4. 3rd Generation BMS Connectors Temperature Sensor CAN BUS line Ignition Feed to Devices (LEM Sensor, Fan, Heater, Internal Contactor) 31215460...

  • Page 22: Lem Sensor And Internal Contactor

    SECTION 2 - SERVICE PROCEDURE LEM Sensor and Internal Contactor The BMS manages the battery pack through two devices: 1. LEM Sensor: LEM Sensor recognizes the amount of current passing through the batteries when charging or the current supply to the electrical motor.
  • Page 23 SECTION 2 - SERVICE PROCEDURE LEM sensors placed at the end of series cells connections are 1. Internal Contactor: A relay to disconnect the bat- shown below. tery pack to the circuit of the machine. The Inter- nal contactor is managed by the BMS by disconnecting the battery circuit to the machine 1st and 2nd Generation in case of failure or incorrect electrical energy...

  • Page 24: Lithium Battery Cell

    SECTION 2 - SERVICE PROCEDURE LITHIUM BATTERY CELL The battery pack is made up of cells as per required power storage. All the cells have the same characteristics and are connected in series by metal plates to get the necessary voltage level.
  • Page 25 SECTION 2 - SERVICE PROCEDURE Cell Feature Nominal Cell Voltage 3.2 V Maximum Cell Voltage 3.65 V Minimum Cell Voltage 2.5 V Cell Capacity 50 Ah Pairs of Cells Capacity 100 Ah Tris of Cells Capacity 150 Ah 150 A (<10s) Max Discharge Current 100 A (Cont) 100 A (<10s)

  • Page 26: Characteristics Of Lithium Batteries

    SECTION 2 - SERVICE PROCEDURE Characteristics of Lithium Batteries MAF11570 The main characteristics of the lithium battery pack are: 3. Another important characteristic of the lithium batteries is the number of complete charge cycle 1. Cells capacity are independent from discharge before the charging capacity decreases.

  • Page 27: Cell Voltage Monitoring

    SECTION 2 - SERVICE PROCEDURE Cell Voltage Monitoring Eight temperature sensors are distributed in the battery pack near the cells to monitor the temperature. Battery Management System (BMS) constantly monitors The BMS activates two fans to cool down the temperature the voltage of every cell.
  • Page 28 SECTION 2 - SERVICE PROCEDURE 38 Volts 100 Ah battery pack 76 Volts 150 Ah battery pack MAF16920 MAF16900 76 Volts 100 Ah battery pack MAF16910 31215460 2-15...
  • Page 29 SECTION 2 - SERVICE PROCEDURE 72 Volts battery pack (Valid for 2nd Gen only) MAF11600 There are 6 temperature sensors on 48V, 11 on 72V and 13 If everything is ok, the BMS feeds the coil of the internal on 83V. The temperature sensors are put on the cells to contactor (relay), so the current can go outside the battery monitor the temperature.

  • Page 30: Cell And Temperature Sensor Location

    SECTION 2 - SERVICE PROCEDURE Cell and Temperature Sensor Location MAF11610 Figure 2-13. 48V Battery Pack - 1st Generation Only MAF16900 Figure 2-14. 76 Volt 150 Amp - 3rd Generation 31215460 2-17...
  • Page 31 SECTION 2 - SERVICE PROCEDURE MAF11620 Figure 2-15. 72V Battery Pack - 1st Generation Only MAF16930 Figure 2-16. X26JP - X770AJ before SN C170001340 83V 100Amp (Esagon Control) 2-18 31215460...
  • Page 32 SECTION 2 - SERVICE PROCEDURE MAF16940 Figure 2-17. X26JP - X770AJ from SN C170001340 76V 100Amp (TTC Control ) 31215460 2-19...
  • Page 33 SECTION 2 - SERVICE PROCEDURE MAF16950 Figure 2-18. X17JP - X550AJ 48V MAF16960 Figure 2-19. X20JP - X600AJ 72V 2-20 31215460...

  • Page 34: Cooling System

    SECTION 2 - SERVICE PROCEDURE The optimal solution in cases of very low temperature is to COOLING SYSTEM use the platform for a few minutes before the charge to heat the battery pack and reduce the charging times or charge the machine after having completed work when the battery pack is still warm.
  • Page 35 SECTION 2 - SERVICE PROCEDURE Upper Section Lower Section MAF11650 In the 1st generation system, the fans are managed by a The two fans are activated at the same time when average timer T1 (shown below) which is controlled by the BMS. temperature of the battery pack is more than 30°C.
  • Page 36 SECTION 2 - SERVICE PROCEDURE Temperature, voltage of the single cells and the system power absorption controls are highlighted. MAF11670 Figure 2-20. 1st Example of BMS Wiring Interface 31215460 2-23...

  • Page 37: Heater System (3Rd Generation)

    SECTION 2 - SERVICE PROCEDURE 2.6 HEATER SYSTEM (3RD GENERATION) Heater - 38V 2 Heaters 60 W each one MAF12880 2-24 31215460...

  • Page 38: Heater - 76V/100Ah

    SECTION 2 - SERVICE PROCEDURE Heater - 76V/100AH MAF12890 31215460 2-25...

  • Page 39: Heater - 76V/150Ah

    SECTION 2 - SERVICE PROCEDURE Heater - 76V/150AH MAF12900 Heater Function • Start at -1°C (or lower); stop at +2°C • Managed automatically by BMS • From -20°C to + 2°C • If SOC <1% they are in any case NOTE: If SOC <...

  • Page 40: Lithium Ion Battery Pack Charger

    SECTION 2 - SERVICE PROCEDURE LITHIUM ION BATTERY PACK CHARGER Battery charger changes the 110/230V, 50/60Hz current coming from the local network to 38/48/72/76/83V DC necessary to charge the cells. The Inverter, the BMS and the battery charger are linked to the CAN BUS cable, The charger receives the required current to supply to the cells from the BMS through the CAN BUS cable.

  • Page 41: Lithium Ion Battery Charger Setting (1St & 2St Gen)

    SECTION 2 - SERVICE PROCEDURE Lithium ION Battery Charger Setting (1st & 2st Gen) Due to difference in the local power supply, the settings on battery charger can change the maximum current drawn from network from 18 A to 30 A. The difference on the setting is the time required for charge.

  • Page 42: Theory Of Battery Charging Condition

    SECTION 2 - SERVICE PROCEDURE Theory of Battery Charging Condition At the start of battery charge, the BMS controls the char- ger to provide the maximum current (as per setting) and The Lithium ION Battery charging operation is a critical as soon as one cell reach the 3630 mV the BMS adjusts the phase because all cells are connected in series and a single charger to reduce the current supply.
  • Page 43 SECTION 2 - SERVICE PROCEDURE MAF12820 1 - V - Battery Voltage 2 - t - Time remained on charge 3 - A - Actual current supplied 4 - Ah - Total current supplied 5 - Red Light - Steady On when charging 6 - Green Light - Blinking when Balancing - Steady On when charged 7 - Display...
  • Page 44 SECTION 2 - SERVICE PROCEDURE MAF16980 38Volt and 48Volt Battery Charger LED Light Meaning charge step - Cells fully charged with the maximum current possible Red Flashing charge step - Cells under charge with reduced current Yellow Flash charge step - Cells under light charge Yellow charge step - Balancing and Maintenance Green/Red Flash...

  • Page 45: Phase - Equalization Or Standby

    SECTION 2 - SERVICE PROCEDURE Phase - Equalization or Standby cell below 3630 mV, while the charger is always charging all other cells. When the condition of one cell reaches the maximum As soon as another cell reaches 3630 mV, the BMS con- value admitted (3630 mV), the BMS connects the cell to nects the new high voltage cell to its resistance as the resistance;...
  • Page 46 SECTION 2 - SERVICE PROCEDURE Charging Current Maximum current required for the battery charger depends on the battery pack voltage and on the local net- work voltage 110 -230V. For CE spec machines, the maximum current is set at: • 25A for 48V battery pack •...

  • Page 47: Battery Charging - Lithium Ion

    SECTION 2 - SERVICE PROCEDURE Battery Charging - Lithium ION If the machine is ON while charging, the LCD display on The condition of the Lithium ION battery is shown on the the platform control station also shows the machine remote control display with the machine power ON, Icon charge indicator.
  • Page 48 SECTION 2 - SERVICE PROCEDURE The charge indicator is also displayed on the Lithium ION side case for 48V and 83V battery pack, while on undercar- riage top frame next to the case, for the 72V battery pack as shown below. This indicator shows the current charge state of the Lithium ION battery pack.
  • Page 49 SECTION 2 - SERVICE PROCEDURE 76 volt 150 Amp 72 volt X 20JP - X600AJ MAF16990 2-36 31215460...

  • Page 50: Lithium Ion Charge Indicator

    SECTION 2 - SERVICE PROCEDURE Lithium ION Charge Indicator The indicator shows the present charge condition of the Lithium ION battery pack as specified in table below. Table 2-5. Lithium ION Battery Charge Indicator Battery Pack 1st Generation 2nd Generation 3rd Generation 38V and 48V Systems 1st phase - recharging with max current available...

  • Page 51: Lead-Acid Battery

    SECTION 2 - SERVICE PROCEDURE Lead-Acid Battery DC-DC Transformer MAF11770 MAF11780 The Lead-acid Battery supplies power to switch on the Figure 2-28. DC-DC for 38V/48V Battery Pack ECM1-2 (1st & 2nd Gen) ECM 1 (3rd Gen) and the BMS. When BMS is ON, it closes the internal contactor and turns ON the DC-DC Transformer which then provides the 12- volt power for the machine system, demanding energy of the lithium pack.

  • Page 52: Electric Motor

    SECTION 2 - SERVICE PROCEDURE Electric Motor On a CCB machine using Lithium ION Battery Pack, there is only one power system and hence one electric motor and The electric motor is a three phase AC motor. It drives the one tandem hydraulic pump.

  • Page 53: Rpm Speed Sensor And Temperature Sensor

    SECTION 2 - SERVICE PROCEDURE RPM Speed Sensor and Temperature Sensor driving, the motor must run at the highest RPMs, while movements such as jib arm or platform rotation need The electric motor has a RPM speed sensor (1) and a tem- requires lower RPMs.

  • Page 54: Inverter And Main Relay

    SECTION 2 - SERVICE PROCEDURE Inverter and Main Relay MAF17020 Figure 2-33. Inverter - 72V/83V/76V 100Amp MAF11820 Figure 2-30. Inverter - 38V/48V Battery Pack MAF11830 Figure 2-34. Inverter - 72V/76V/83V Battery Pack NOTE: 72V/76/V/83V 100Amp RPM motor adjustment by relay contacts. MAF17000 NOTE: 76V 150 Amp RPM motor adjustment via CAN BUS.
  • Page 55 SECTION 2 - SERVICE PROCEDURE MAF11840 Figure 2-35. External Main Contactor 3. To supply and control the electric motor. The inverter controls the electric motor through an rpm sensor and a temperature sensor located on the motor. It reduces the rpm when power required is high.

  • Page 56: Relays

    SECTION 2 - SERVICE PROCEDURE RELAYS MAF11850 MAF11860 Figure 2-37. Relay Figure 2-36. Relay Location Table 2-7. Relay Function Relay 48VBattery Pack 72V/83V Battery Pack 38V/76V Battery Pack Number BMS Activation BMS Activation BMS Activation Connection Lead-acid Battery to DC-DC Connection Lead-acid Battery to DC-DC Inverter Running Consent BC Activation from BMS 31215460...

  • Page 57: Can Bus Communication

    SECTION 2 - SERVICE PROCEDURE CAN BUS Communication CAN Bridge Box (X700AJ and X23J only) The battery pack has a CAN BUS line that connects the The CAN Bridge Box is installed only on the 72 Volt Battery BMS to the Battery charger and Inverter. This CAN BUS Pack.

  • Page 58: Lithium Battery Condition Display Icon And Warning Purposes

    SECTION 2 - SERVICE PROCEDURE Lithium Battery Condition Display Icon and NOTE: It is possible to use all functions and the system error icon disappears when the machine is restarted. Warning Purposes Some icons displayed on LCD display screen are shown On LITHIUM ION machines, during start and machine below.
  • Page 59 SECTION 2 - SERVICE PROCEDURE 4. Extra Low Speed Check the Error Menu in remote control diagnos- tic when this icon is displayed. MAF11910 MAF12010 5. Battery Percentage When the lower temperature of any cell falls below 0 °C (32 °F), the machine runs in low mode only;...

  • Page 60: Emergency Electric Motor Override

    SECTION 2 - SERVICE PROCEDURE EMERGENCY ELECTRIC MOTOR OVERRIDE NOTICE The electric motor can be activated in an emergency (run- DURING THE OVERRIDE, THE SAFETY CONTROLS OF THE MACHINE ARE ning at min RPM) with a by-pass on the electrical system. NOT ACTIVE.
  • Page 61 SECTION 2 - SERVICE PROCEDURE MAF12040 Figure 2-39. Electrical Motor Bypass 2-48 31215460...
  • Page 62 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 63: Troubleshooting And Fault Codes

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES SECTION 3. TROUBLESHOOTING AND FAULT CODES FAULT CODES Press Button 6 on the remote control (service), then press button 3 (errors), then press button 1 (prev) until the Battery charger, Inverter and BMS have a self diagnosis below page is on display.

  • Page 64: Bms Fault Codes (1St And 2Nd Generation Battery Pack)

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES Table 3-1. BMS Fault Codes (1st and 2nd Generation Battery Pack) Error Code Error Description System Configuration Error Unexpected Voltage Unexpected Temperature Overcurrent Discharge Overcurrent Charge Pre-charge Error No 12 Volt Supplies No 12 Volt Supplies Battery Over temperature Electronics Over temperature Bad Temp Sensor Auto Shut Off Mode...

  • Page 65: Bms Fault Codes (3Rd Generation Battery Pack)

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES Table 3-2. BMS Fault Codes (3rd Generation Battery Pack) CODE (DEC) CODE (HEX) Error Description OVER-VOLTAGE: HIGHEST CELL >= 3650mV (till 3800mV is allowed the discharge at the next 0001 connection) UNDER-VOLTAGE: LOWEST CELL <= 2850mV (till 2000mV is allowed the charge at the next 0002 connection) 0004...

  • Page 66: Inverter Fault Codes

    Table 3-3. Inverter Fault Codes Error Code Error Condition Error Description Corrective Action Wrong Config Eeprom memory not configured. Contact JLG. Watch Dog The inverter is not able to Control connections and activate or turn off the electric continuity of the electric motor. If motor.
  • Page 67 High temperature Temperature rise in the inverter. Allow better cooling to the inverter. If the anomaly remains, contact JLG. Motor temperat High motor temperature. Stop the machine temporarily to enable motor cooling. Can Bus KO...
  • Page 68 SECTION 3 - TROUBLESHOOTING AND FAULT CODES Table 3-3. Inverter Fault Codes Error Code Error Condition Error Description Corrective Action Driver shorted Anomaly to the relay supply. Control relay supply. Usually it is a temporary anomaly due to a working condition. In case the anomaly persists replace the inverter.
  • Page 69 Replace the batteries with the detected batteries not in original one only. conformity. Current sensor KO Max current setup procedure Contact JLG. active. Analog Input Problem on the A/D conversion of It should be a temporary error, if the problem occurs permanently...

  • Page 70: Battery Charger Fault Codes (38/48/72/83V Battery Pack)

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES Table 3-4. Battery Charger Fault Codes (38/48/72/83V Battery Pack) Error Code Error Description Status Corrective Action Internal logical Fault Battery charger stops working. Contact service dept. Or change product. Communication problem with Battery charger stops working. Contact service dept.
  • Page 71 SECTION 3 - TROUBLESHOOTING AND FAULT CODES Table 3-4. Battery Charger Fault Codes (38/48/72/83V Battery Pack) Error Code Error Description Status Corrective Action Power failure Battery charger stops supplying If problem persists, check detected Power. Operation resumes battery charger mains as soon as alarm conditions power supply.

  • Page 72: Battery System Troubleshooting (1St & 2Nd Gen)

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES BATTERY SYSTEM TROUBLESHOOTING (1ST & Check the voltage on the 12V switch under the key switch. IF red wire to the ground has 12 Volt, 2ND GEN) go to step 4, if not go to step 5. NOTICE IN CASE OF BATTERY PACK PROBLEMS PLEASE REFER TO THE TROUBLE- SHOOTING FOR 48 VOLT BATTERY PACK OR 72 VOLT BATTERY PACK AS APPLI-...
  • Page 73 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 9. Battery charger works ok, but the battery level 6. Connect the power cable, the battery charger light is red after two minutes. indicated on the display remains “zero”. The system works correctly. Keep the power If wrench icon appears on the display as shown cable connected until the light on the battery below, go to step 10, if not go to step 17.
  • Page 74 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 17. Wrench icon does not show on the display. D - It is not possible to charge the battery pack- Check fuse F1, then check if the relay coils of R1 and R4 have 12 volts with the key switch ON. If Red/green light is present on the battery char- ger LED during the charge, go to step 7.
  • Page 75 SECTION 3 - TROUBLESHOOTING AND FAULT CODES reaches 3630 mV and then it reduces the cur- b. Lowest: It is the lowest cell (Volt). It should be more than 3550 mV. Normally this data rent. All the cells are connected in series, so BMS concerns only one cell.
  • Page 76 SECTION 3 - TROUBLESHOOTING AND FAULT CODES G - Ventilation fans do not work I - Plug icon on the display interchanges continu- ally with the battery icon while charging Check fuse F2 and check the fan timer “T1”. If they are ok, check connection from the 12 Volt Lead-acid battery to the BMS (Feed connector –...

  • Page 77: Battery Pack (Sn C170000330 To Present)

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES 48V Battery Pack (SN C170000330 to Present) 4. Red wire has 12 Volt Check the 12 Volt switch under the key switch, A - Remote control display is OFF and check the connection of the wire OR0400 (or 1/12), from the key switch to the pin B1 in the 1.
  • Page 78 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 11. Inverter trouble code is number “80”. the connection from the “5 ways BMS connector and the BMS. Check fuse F4, then check the electric line of the If all the connections and supply are ok, go to fuse F4.
  • Page 79 SECTION 3 - TROUBLESHOOTING AND FAULT CODES C - Electric Motor does not run 20. Battery charger works correctly, but the battery level never reaches 100%. If battery package level is “zero”, go to failure Connect the 120-220V power cable and keep it description B.
  • Page 80 SECTION 3 - TROUBLESHOOTING AND FAULT CODES When a new cell reaches 3630 mV the BMS will After reading the above values, check the below window: connect it to its resistance, so at the end all the cells will be charged at the same level and have the same performances.
  • Page 81 SECTION 3 - TROUBLESHOOTING AND FAULT CODES G - Ventilation fans do not work I - Plug icon on the display interchanges continu- ally with the battery icon while charging Check fuse F2 and check the fan timer “T1”. If they are ok, check connection from the 12 Volt Lead-acid battery to the BMS (Feed connector –...

  • Page 82: Battery Pack (Prior To Sn C170000352)

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES 72V Battery Pack (Prior to SN C170000352) 4. Red wire has 12 Volt Check the 12 Volt switch under the key switch, A - Remote control display is OFF and check the connection of the wire 1/12, from the key switch to the pin B1 in the master board.
  • Page 83 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 9. Battery charger works correctly, but the battery 7. Connect the power cable, the light on the bat- tery charger flashes red/green after two minutes. level indicated on the display remains “zero”. This condition indicates the battery charger If wrench icon appears on the display as shown does not find the 72V battery package.
  • Page 84 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 17. Wrench icon does not show on the display. D - It is not possible to charge the battery pack- Check fuse F1, then check if the relay coils of R1 and R4 have 12 volts with the key switch ON. If Red/green light is present on the battery char- ger LED during the charge, go to step 7.
  • Page 85 SECTION 3 - TROUBLESHOOTING AND FAULT CODES The BMS allows the charger to provide the maxi- b. Lowest: It is the lowest cell (Volt). It should be more than 3550 mV. Normally this data mum current (13 or 30 A) until the first cell concerns only one cell.
  • Page 86 SECTION 3 - TROUBLESHOOTING AND FAULT CODES G - Ventilation fans do not work I - Plug icon on the display interchanges intermit- tently with the battery icon while charging Check fuse F2 and check the fan timer “T1”. If they are ok, check connection from the 12 Volt Lead-acid battery to the BMS (Feed connector –...

  • Page 87: Battery Pack (Sn C170000352 To Present)

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES 72V Battery Pack (SN C170000352 to Present) 4. Red wire has 12 Volt Check the 12 Volt switch under the key switch, A - Remote control display is OFF and check the connection of the wire OR0400 (or 1/12), from the key switch to the pin B1 in the 1.
  • Page 88 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 7. Connect the power cable, the light on the bat- 9. Battery charger works ok, but the battery level tery charger flashes red/green after two minutes. indicated on the display remains “zero”. This condition indicates the battery charger If wrench icon appears on the display as shown does not find the 72V battery package.
  • Page 89 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 17. Wrench icon does not show on the display. D - It is not possible to charge the battery pack- Check fuse F1, check if the relay coils of R1 and R2 have 12 volts with the key switch ON. If Red/green light is present on the battery char- ger LED during the charge, go to step 7.
  • Page 90 SECTION 3 - TROUBLESHOOTING AND FAULT CODES The BMS allows the charger to provide the maxi- b. Lowest: It is the lowest cell (Volt). It should be more than 3570 mV. Normally this data mum current (13A or 30 A) until the first cell concerns only one cell.
  • Page 91 SECTION 3 - TROUBLESHOOTING AND FAULT CODES G - Ventilation fans do not work I - Plug icon on the display interchanges intermit- tently with the battery icon while charging Check fuse F2. If ok, check connection from the 12 Volt Lead-acid battery to the BMS (Feed con- nector –...

  • Page 92: Ramhino Diagnostic Tool

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES RAMHINO DIAGNOSTIC TOOL RamHino is an application which allows communication with the CAN BUS circuit of the machine. A Peak CAN device is used for connection between the PC/laptop and the machine CAN BUS circuit. The tool is useful for service on lithium machines, as it shows detailed overview of the battery pack status and how the pack components are working.

  • Page 93: Peak Can Device Connection

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES Peak CAN Device Connection For models X14J, X19J, X23J, X390AJ, X550AJ and X700AJ Connect Pack Can device to the cable of remote control at the ground port on the side. MAF12170 For modelsX17JP, X500AJ, X20JP, X600AJ, X26JP and X770AJ Connect the Peak Can device to the port of the remote control at the ground port on the side.

  • Page 94: Ramhino Startup Procedure

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES Turn ON the Battery Switch and turn ON the Circuit Breaker Switch. MAF12190 RamHino Startup Procedure • Select the applicable machine model from the win- Run the RAMHINO Flash Program through the dow menu “Machine”. icon on desktop.

  • Page 95: Folder Data

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES Folder Data If there is no communication between PC/laptop and machine system, data will not be displayed on the screen. The first screen indicates the data exchange between the In such case do the following: machine system and the PC/laptop.

  • Page 96: Lithium Battery System Page

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES Select the applicable machine model and click on “Lith- temperature sensor location are shown on 48V bat- ium Battery System” tab. tery pack page while cell number and temperature sensor position are shown on 72/83V battery pack NOTE: 48V battery pack and 72/83V battery pack have the page.
  • Page 97 SECTION 3 - TROUBLESHOOTING AND FAULT CODES MAF12240 Figure 3-2. 72/83V Battery System page - 1st and 2nd Generation MAF12830 Figure 3-3. 38V Battery System page - 3rd Generation 31215460 3-35...

  • Page 98: Ramhino Parameters

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES RamHino Parameters 3600 mV (average value). Figure 3-6 shows the range of admissible voltages. Lithium System parameters for RamHino Lithium sys- NOTE: When the cells are not under charge or under dis- tem are shown below charge for some time, they try to reach a nominal RamHino First group: value of approximately 3300 mV irrespective of their...

  • Page 99: Bms Current Requirement

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES 3. SOC (%): It is the level of battery pack charge and 2. DMCC (A): It is the current by the BMS from the battery charger. It depends on the cells and corresponds to the value showed by the remote charging status.
  • Page 100 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 2. Lowest - at: It is the voltage at the lowest cell. Second Group - Cell Voltage (mV) The number of the corresponding cell is indi- Delta (mV): It is the difference between the highest cell cated on side.
  • Page 101 SECTION 3 - TROUBLESHOOTING AND FAULT CODES 4. Average: It is the average of the total cell values 3. Highest at: It is the voltage at the highest cell. (Volt). At the end of the equalization phase, it The number of the highest cell is indicated on should be around 3580/3600 Volt.
  • Page 102 SECTION 3 - TROUBLESHOOTING AND FAULT CODES Third Group - Temperature Sensors Fourth Group - Contactor Opening (only for 2nd Generation BMS) MAF12300 Open: Current supply is not allowed. Closed: Current supply is allowed. Internal contactor status called “Main Contactor”, MAF12280 is controlled by the BMS.
  • Page 103 SECTION 3 - TROUBLESHOOTING AND FAULT CODES Sixth Group - Relays (only for 1st Generation Eighth Group - BMS Status (only for 1st Genera- BMS) tion BMS) The relays are inside the BMS and hence cannot The following parameters are internal to the be accessed.

  • Page 104: Start Log

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES START LOG Click the icon to stop recording data. The file gener- ated should be opened in Excel format and the Lithium battery Click the icon to start recording the data applicable pack data stored every second can be visualized with the time [hhmmss].

  • Page 105: Dmcc (A) And Cell Capacity Setting

    SECTION 3 - TROUBLESHOOTING AND FAULT CODES DMCC (A) and Cell Capacity Setting MAF12360 31215460 3-43...
  • Page 106 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

This manual is also suitable for:

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