JLG 1230ES, Service And Maintenance Manual

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SECTION 5 - CONTROL COMPONENTS
5-10 – JLG Lift – 3121222
Power Module Diagnostics
The Power Module has the ability to detect many fault sce-
narios and communicate them to the JLG Analyzer. Useful
diagnostic information can also be determined from the
Green LED located on the Power Module.
1. OPEN CIRCUIT LINE CONTACTOR (3-1)
a. The Power Module's Line Contactor Drive
Circuitry passed power-up self-tests, but the
Line Contactor did not close when ener-
gized.
b. May signal an open-circuit bB and
the Line Contactor, a faulty Line Contactor,
or an open-circuit between the Line Contac-
tor and the Power B Terminal.
c. 4 Flashes on Power Module.
d. Drive, Steer, & Lift Up Prevented.
2. CONTACTOR DRIVER PERMANENTLY OFF (3-1)
a. The Power Module's Line Contactor Drive
Circuitry failed to energize during power-up
self-tests.
b. May indicate a faulty Line Contactor, diffi-
culty with Line Contactor coil wiring, or a
faulty Power Module.
c. No Flash Code on Power Module.
d. Drive, Steer, & Lift Up Prevented.
3. LINE CONTACTOR MISWIRED ON OR WELDED
(3-2)
a. The Power Module's Line Contactor Drive
Circuitry passed power-up self-tests, but the
Line Contactor was closed at power-up or
failed to open when de-energized.
b. May indicate a faulty Line Contactor, diffi-
culty with Line Contactor coil wiring, or diffi-
culty with power wiring.
c. 4 Flashes on Power Module.
d. Drive, Steer, & Lift Up Prevented.
4. CONTACTOR DRIVER PERMANENTLY ON (3-2)
a. The Power Module's Line Contactor Drive
Circuitr y failed to de - energize during
power-up self-tests.
b. May indicate difficulty with Line Contactor
coil wiring, or a faulty Power Module.
c. No Flash Code on Power Module.
d. Drive, Steer, & Lift Up Prevented.
5. POWER MODULE TOO HOT - PLEASE WAIT (4-
2)
a. The Power Module for Drive, Steer, and Lift
Up has reached thermal cutout. Allow to
cool by powering down.
b. May indicate that the vehicle is operating in
extremely high ambient temperatures, or a
faulty Power Module.
c. 8 Flashes on Power Module.
6. DRIVING AT CUTBACK -- POWER MODULE
CURRENT LIMIT (4-2)
a. The Traction portion of the Power Module
has reached thermal limit. Allow to cool by
waiting for temperature to fall.
b. May indicate that the vehicle is operating on
excessive grades, or there is a drive motor
issue that causes high armature current
(brake applied when driving, short-circuited
armature, etc).
c. 8 Flashes on Power Module.
7. LIFT UP AT CUTBACK -- POWER MODULE CUR-
RENT LIMIT (4-2)
a. The Pump portion of the Power Module has
reached thermal limit. Allow to cool by wait-
ing for temperature to fall.
b. May indicate that the vehicle's lift function is
being used outside duty cycle consider-
ations, or there is a pump motor issue that
causes high current (worn brushes, worn
commutator, etc).
c. 8 Flashes on Power Module.
8. BATTERY VOLTAGE TOO LOW - SYSTEM SHUT-
DOWN (4-4)
a. Battery Voltage momentarily dropped
below 14.5V. With a low battery charge, this
can occur during heavy current demand
due to Drive, Steer, or Lift Up. Recharge bat-
teries or check for damaged batteries.
b. May indicate low battery charge, a battery
charger issue, or a power wiring issue.
c. 7 Flashes on Power Module.
d. Drive, Steer, & Lift Up Prevented.
9. BATTERY VOLTAGE TOO HIGH - SYSTEM SHUT-
DOWN (4-4)
a. The Power Module momentarily measured
excessively high Battery Voltage (>37.0V)
and the Ground Module de-energized the
Ignition Relay to protect system devices.
This may be due to improper battery charg-
ing or incorrect voltage batteries being
used.
b. May indicate a battery charger issue, wrong
battery type is installed, or a faulty Power
Module.
c. 7 Flashes on Power Module.
d. Drive, Steer, & Lift Prevented.