JLG DVSP Series Service Manual - Manual (Page 53)

SECTION 3 - BASE COMPONENTS
3121136 – JLG Lift – 3-23
Battery Testing Can Be Performed In Two Ways:
1. The batteries can be tested using a battery tester
capable of testing 12V 100Ah AGM VRLA (Valve
Regulated Lead Acid) batteries, using the instruc-
tions of the battery tester manufacturer.
2. If an appropriate battery tester is unavailable, the
batteries can be tested by fully charging them with
the charger that is installed in the machine. Then
check the battery voltage of each battery - 4 hours -
after charging is complete. Batteries less than 12.72
volts should be replaced.
NOTE: If a faulty charger is suspected, the batteries can be
charged using a charger that supplies 2.45 volts/
cell. Charging should be terminated when the
charge current drops below 1 amp.
Battery Replacement
Replacement battery(s) must be of equivalent voltage and
amperage output as the OEM battery(s) in order for the
machine to operate to as manufactured specifications.
Battery replacement part weight must also be 65 lb.
(30Kg) in order to maintain machine stability as manufac-
tured.
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BAT-
TERIES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION.
DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Battery Charger General Information
IMPORTANT
DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF
MACHINE IS STILL UNDER WARRANTY. OPENING THE BATTERY
CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID
THE CHARGER WARRANTY. IF UNDER WARRANTY REQUEST A
REPLACEMENT CHARGER FROM THE FACTORY.
ALSO BEFORE REPLACING ANY COMPONENT, USE THE CHARGER
MANUFACTURERS TROUBLESHOOTING GUIDE SHIPPED WITH THE
MACHINE TO CHECK THE INTERNAL AC AND DC CIRCUITS AND
DETERMINE WHICH COMPONENT HAS FAILED. A WIRING DIAGRAM
FOR THIS MODEL DUAL VOLTAGE-SCR CHARGER IS INCLUDED AT
THE END OF THIS SECTION OF THE MANUAL, SEE FIGURE 3-10.
The DVL and DVSP battery charger allows for replacement
of the following internal components. Consult your Illus-
trated Parts Manual for part numbers of these components
which are available from the JLG Parts Department:
• Transformer
• Printed Circuit Board
• Shunt Assembly
• Interlock Relay
• SCR Rectifier
• AC Circuit Breaker
• DC Circuit Breaker
• AC Voltage Selector Switch
• Wet/VRLA Charging Profile Selector Switch
Replacement and troubleshooting of these components
requires removal of the battery charger from it’s mounting
position on the machine.
Battery Charger Troubleshooting
If batteries are not charging properly use the following
steps to assist in resolving the problem.
1. Be sure the charger is plugged into the proper
receptacle and there is power to that receptacle.
2. Be sure all battery connections are tight.
3. If charger does not come on, check connections at
the charger. Make sure all connections are tight.
4. If charging over night, ensure there is power to the
receptacle at all times and not being turned off at the
end of the shift.