JLG 10MSP Service Manual - Manual (Page 61)

SECTION 3 - BASE COMPONENTS
3121228 – JLG Lift – 3-29
Battery Charger General Information
DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER
IF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT-
TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY
WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY
REQUEST A REPLACEMENT CHARGER FROM THE FACTORY.
Battery Charging Status Indicators
The battery charging status LED indicators are located
next to the charger AC input receptacle on the rear bum-
per of the machine. This LED indicator set is plugged
directly into a connector on the back of the battery char-
ger and indicates current charging status.
When first plugged in, the charger will automatically turn
on and go through a short LED indicator self-test (all
LED’s will flash in an up-down sequence for two seconds),
then charging will begin.
1. The YELLOW ‘CHARGING’ LED will turn on and a
trickle current will be applied until a minimum volt-
age is reached.
Once a minimum battery voltage of 2 volts per cell is
detected, the charger will enter the bulk charging
constant-current stage and the YELLOW ‘CHARG-
ING’ LED will remain on. The length of charge time
will vary by how large and how depleted the battery
pack is, the input voltage (the higher, the better),
and ambient temperatures (the lower, the better). If
the input AC voltage is low (below 104VAC), then the
charging power will be reduced to avoid high input
currents. If the ambient temperature is too high, then
the charging power will also be reduced to maintain
a maximum internal temperature.
2. When the GREEN ‘CHARGED’ LED turns on, the
batteries are completely charged.
The charger may now be unplugged from AC power
(always pull on plug and not cord to reduce risk of
damage to the cord). If left plugged in, the charger
will automatically restart a complete charge cycle if
the battery pack voltage drops below a minimum
voltage or 30 days has elapsed.
3. If a fault occurred anytime during charging, a fault
indication is given by flashing the RED ‘FAULT’ LED
with a code corresponding to the error.
There are several possible conditions that generate
errors. Some errors are serious and require human
intervention to first resolve the problem and then to
reset the charger by interrupting AC power for at
least 10 seconds. Others may be simply transient
and will automatically recover when the fault condi-
tion is eliminated. To indicate which error occurred,
the RED ‘FAULT’ LED will flash a number of times,
pause, and then repeat.
[1 FLASH] Battery Voltage High: auto-recover. Indi-
cates a high battery pack voltage.
[2 FLASH] Battery Voltage Low: auto-recover. Indi-
cates either a battery pack failure, battery pack is not
connected to charger, or battery volts per cell is less
than 0.5 VDC. Check the battery pack and battery
pack connections.
[3 FLASH] Charge Timeout: Indicates the battery
did not charge within the allowed time. This could
occur if the battery is of a larger capacity than the
algorithm is intended for. It can also occur if the bat-
tery pack is damaged, old, or in poor condition. In
unusual cases it could mean charger output is
reduced due to high ambient temperature.
[4 FLASH] Check Battery: Indicates the battery
pack could not be trickle charged up to the mini-
mum 2 volts per cell level required for the charge to
be started. This may also indicate that one or more
cells in the battery pack are shorted or damaged.
[5 FLASH] Over-Temperature: auto-recover. Indi-
cates charger has shutdown due to high internal
temperature which typically indicates there is not
sufficient airflow for cooling – see step 1 of Installa-
tion Instructions. Charger will restart and charge to
completion if temperature is within accepted limits.
[6 FLASH] QuiQ Fault: Indicates that the batteries
will not accept charge current, or an internal fault
has been detected in the charger. This fault will
nearly always be set within the first 30 seconds of
operation. Once it has been determined that the bat-
CHARGING
YELLOW(MIDDLE) LED ON
Charge Incomplete
CHARGE COMPLETE
GREEN (TOP) LED ON
100% Complete
CHARGING PROBLEM
RED (BOTTOM) LED ON
See Flash Codes following