JLG 1230ES Service Manual - Manual (Page 85)

SECTION 5 - CONTROL COMPONENTS
3121222 – JLG Lift – 5-9
Power Module Diagnostics
The Power Module has the ability to detect many fault sce-
narios and communicate them to the JLG Analyzer. Use-
ful 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 Cir-
cuitry passed power-up self-tests, but the Line
Contactor did not close when energized.
b. May signal an open-circuit between +B and the
Line Contactor, a faulty Line Contactor, or an
open-circuit between the Line Contactor and the
Power Module +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 Cir-
cuitry failed to energize during power-up self-
tests.
b. May indicate a faulty Line Contactor, difficulty
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 Cir-
cuitry 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, difficulty
with Line Contactor coil wiring, or difficulty 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 Cir-
cuitry 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 CUR-
RENT 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 waiting
for temperature to fall.
b. May indicate that the vehicle's lift function is
being used outside duty cycle considerations, 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 batteries or check
for damaged batteries.
b. May indicate low battery charge, a battery char-
ger 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 charging or incorrect
voltage batteries being used.
b. May indicate a battery charger issue, wrong bat-
tery type is installed, or a faulty Power Module.
c. 7 Flashes on Power Module.
d. Drive, Steer, & Lift Prevented.