JLG 1230ES Service Manual - Manual (Page 99)

SECTION 5 - CONTROL COMPONENTS
3121222 – JLG Lift – 5-23
Excessive Battery Watering Requirements or
Strong Sulphur (Rotten Egg) Smell
These symptoms indicate over-charging or high battery
temperature. These symptoms are unlikely to be caused
by too high a charge current since the maximum charge
current of the charger will be small compared to even a
moderately sized battery pack. The most likely cause for
this problem is incorrect charge algorithm setting and/or
high ambient temperatures.
1. Confirm that the battery pack is not too small - usu-
ally > 50Ah.
2. Confirm that the nominal battery voltage matches
the charger output voltage.
3. Confirm the correct battery charge algorithm. If the
battery pack is new, the algorithm will need to be
changed if the pack is not the same as the old one.
for instructions on how to determine and change the
battery charge algorithm see the following sub-sec-
tion.
4. If the output voltage of the charger seems excessive,
return the charger for service. Contact JLG to get the
expected battery voltage settings for the charger in
question. Be sure to have the charger’s serial num-
ber and charge algorithm setting available when
calling.
Checking/Changing the Battery Charge Algo-
rithm
The charger is pre-loaded with programming algorithms
for the specific batteries detailed in Table 5-5, Battery
Algorithms. Contact JLG if your specific battery model is
not listed.
Each time AC power is applied with the battery pack not
connected, the charger enters an algorithm select/display
mode for approximately 11 seconds. During this time, the
current Algorithm # is indicated on the Yellow Charging
LED. A single digit Algorithm # is indicated by the number
of blinks separated by a pause. A two digit Algorithm # is
indicated by the number of blinks for the first digit followed
by a short pause, then the number of blinks for the second
digit followed by a longer pause.
To check / change the charging algorithm:
1. Disconnect the charger positive connector from the
battery pack. Apply AC power and after the LED test,
the Algorithm # will display for 11 seconds.
2. To change the algorithm, touch the connector to the
battery’s positive terminal for 3 seconds during the
11 second display period and then remove. The
Algorithm # will advance after 3 seconds. Repeat
this procedure until the desired Algorithm # is dis-
played. A 30 second timeout is extended for every
increment. Incrementing beyond the last Algorithm
will recycle back to the first Algorithm. When the
desired Algorithm is displayed, touch the charger
connector to the battery positive terminal until the
output relay makes a clicking noise (approx. 10 sec-
onds). The algorithm is now in the permanent mem-
ory.
3. Remove the AC power from the charger and recon-
nect the charger’s positive connector to the battery.
It is recommended to check a newly changed algo-
rithm by repeating the above steps 1 and 3.
Table 5-5. Battery Algorithms
Algorithm # Battery Type
43 Harris Battery Discover EVGC6A-A
35 JLG P/N 0400242
23 Douglas Flooded (JLG default)
GES Battery A1055
Trojan T105
East Penn GC-110-WNL
Trojan T105 PLUS
Champion CHGC2 GC2
US BATT EV-145-WNL
US BATT 2200 XC
8 Concorde 10xAh AGM
7 J305 DV/DT CP
6 DEKA 8G31 Gel
5 Trojan 30/31XHS
4 US Battery USB2200
3 T105 DV/DT CP
2 Trojan T105 tapped
1 Trojan T105