JLG 3246ES Service Manual - Manual (Page 85)

SECTION 3 - CHASSIS & SCISSOR ARMS
3121166 – JLG Lift – 3-49
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 informa-
tion 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 informa-
tion in the Inverter/Charger manual. First, go through
the troubleshooting 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 clockwise 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 connec-
tor 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 Module 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 posi-
tion.
2. Disconnect control cable from the Inverter/Char-
ger.
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
terminal 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 posi-
tion 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
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 cir-
cuit 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
connector 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 Inter-
lock 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.