JLG X1000AJ-X33JP, Supplement Manual

Page 1: ...X19J X700AJ X23J X370AJ X13JP X430AJ X15JP X500AJ X17JP X600AJ X20JP X770AJ X26JP X1000AJ X33JP See inside cover for serial break information 31215460 October 14 2019 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 2: ...with a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 3: ...2 to Present X370AJ X13JP X430AJ X15JP X500AJ X17JP All X600AJ X20JP All X770AJ X26JP X1000AJ X33JP Models 83V Gen 2 38V Gen 3 76V 100Ah Gen 3 76V 150Ah Gen 3 X390AJ X14J X550AJ X19J X700AJ X23J X370AJ X13JP All X430AJ X15JP All X500AJ X17JP X600AJ X20JP X770AJ X26JP Prior to SN C170001340 SN C170001340 to Present X1000AJ X33JP All G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o ...

Page 4: ...E USE CLASS D FIRE EXTINGUISHER IN CASE OF FIRE HAZARD The CCB using Gasoline Diesel or Lithium ION batteries have the same structure functionality and the same hydraulic electrical and electronic systems The CCB with dual power configuration Gasoline Diesel and electrical motor are coupled with two tandem pumps while those with the Lithium ION have only one tandem pump driven by an electrical mot...

Page 5: ...INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A 2 31215460 REVISON LOG Original Issue A October 14 2019 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 6: ...Cell Voltage Monitoring 2 14 Cell and Temperature Sensor Location 2 17 2 5 COOLING SYSTEM 2 21 Case Cooling Air Flow 2 21 2 6 HEATER SYSTEM 3RD GENERATION 2 24 Heater 38V 2 24 Heater 76V 100AH 2 25 Heater 76V 150AH 2 26 Heater Function 2 26 2 7 LITHIUM ION BATTERY PACK CHARGER 2 27 Lithium ION Battery Charger Setting 1st 2st Gen 2 28 Battery Charging and Discharging 2 28 Theory of Battery Charging...

Page 7: ...330 to Present 3 15 72V Battery Pack Prior to SN C170000352 3 20 72V Battery Pack SN C170000352 to Present 3 25 3 3 RAMHINO DIAGNOSTIC TOOL 3 30 Peak CAN Device Connection 3 31 RamHino Startup Procedure 3 32 Folder Data 3 33 Lithium Battery System Page 3 34 RamHino Parameters 3 36 3 4 START LOG 3 42 DMCC A and Cell Capacity Setting 3 43 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 8: ...SN C170001340 76V 100Amp TTC Control 2 19 2 18 X17JP X550AJ 48V 2 20 2 19 X20JP X600AJ 72V 2 20 2 20 1st Example of BMS Wiring Interface 2 23 2 21 Battery Pack Charger 2 27 2 22 83V Battery Pack Charger 2nd Generation 2 27 2 23 76V Battery Pack Charger 3rd Generation 2 27 2 24 Battery Charger Setting 2 28 2 25 Charger Set 3rd Gen 2 28 2 26 Charging Phases 2 29 2 27 Charge Indicator 76 Volt 100 or ...

Page 9: ... 2 5 Lithium ION Battery Charge Indicator 2 37 2 6 Electric Motor Characteristics 2 39 2 7 Relay Function 2 43 3 1 BMS Fault Codes 1st and 2nd Generation Battery Pack 3 2 3 2 BMS Fault Codes 3rd Generation Battery Pack 3 3 3 3 Inverter Fault Codes 3 4 3 4 Battery Charger Fault Codes 38 48 72 83V Battery Pack 3 8 3 5 Battery Charger Fault Codes 76V Battery Pack 3 9 3 6 Admissible Voltage Range 3 36...

Page 10: ...Table 1 2 Cell Features Lithium System Release Lithium System 1 Lithium System 2 Lithium System 3 CellCapacity 100Ah 100 Ah 50 Ah Pair 100 Ah Trio 150 Ah BatteryPackTotalVoltage 48V 72V 83V 38 76V MachineSystemVoltage 12V DOD Depthof Discharge 80 90 NominalVoltage 3 2V MaximumVoltage 3 65V X26JP X770AJ X33JP X1000AJ MinimumVoltage 2 5Volt MaximumDischargeCurrent 150A 10s 100A cont 50A cont NoofCyc...

Page 11: ... 48V Pack Upper Section 1st Generation MAF11340 Figure 1 2 48V Pack Upper Section 2nd Generation MAF11330 Figure 1 3 72V Pack Upper Section 1st Generation MAF11350 Figure 1 4 72V 83V Pack Upper Section 2nd Generation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 12: ...8 72 76 83VoltDCto13 5Volt FNo FuseNumberIdentification INV Inverter Led BatteryChargerLamp MR ExternalMainConductor RNo RelayNumberIdentification T1 TimerforFans Table 1 4 Battery Charger Type 110V or 220V 10 50 60 Hz IndicativeTimetoRecharge 2 to 4 hrs for 80 Recharge ElectricSystem 38 48 72 76 83V LithiumBatteryPack 12V MachineSystems ElectricMotor 38V 3 Phase 2000 Watt 48V 3 Phase 2000 Watt 72...

Page 13: ...with a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 14: ... starts Once the engine starts the engine driven generator provides 13 5V electrical power for the machine components and recharges the battery When the engine is not running connect 120 230V AC power cord into a power receptacle to recharge the bat tery When the Battery Management System BMS is ON the DC DC converter also switches ON When this occurs the DC DC converter powered by the Lithium ION...

Page 15: ...o supply the electrical motor When the internal and external contactors L M are closed current from the Lithium battery pack is supplied to the Inverter N Current is supplied to the electric motor G according to the speed demand from the signal O from the ECM1 2 B and the reserve of existing bat tery power and is controlled by the BMS A The BMS regulates the amount of current coming IN recharge an...

Page 16: ... the system in case of failure Protect the cells from overcharge over discharge over temperature overvoltage under voltage 48V 72V Systems with 1st Generation BMS The 1st generation BMS is the same for 48V and 72V sys tems but they are not interchangeable The BMS is a device composed of electronic cards assembled together in a box as the image below Monitoring boards can manage maximum 12 Lithium ...

Page 17: ... BMS Connectors J1 CAN BUS Module Socket J2 Current Sensor Socket LEM J3 Power and Contactor Socket J4 Temperature Sensor Socket J5 Voltage Cells Measurements Socket Resistance to Discharge the Cells during the Equalization Phase G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 18: ...can manage maximum 16 cells Both cards have the same functions but manage a defined group of cells BMS Mas ter and Slave are identified with letters M and S stamped on side case as shown below Table 2 2 Internal Connector Identification on BMS module J1 Temperature Input 1 J2 Temperature Input 2 J3 Temperature Input 3 J6 Voltage Input J7 Internal Contactor and Fans J8 LEM Sensor J9 Power Supply J1...

Page 19: ...verheat ing On the 1st Generation BMS the temperature sensors are located on the board cards and the internal battery con tact is opened when the temperature reaches 60 C MAF11490 48 Volt Battery Pack Table 2 3 2nd Generation BMS Connectors J1 J2 J3 Temperature Sensor Sockets J6 Voltage cells Measurements Socket Resistance to discharge the cells during the Equalization phase J7 Internal contactor ...

Page 20: ... Generation BMS The 3rd Generation BMS can be arranged with one or two electronic cards The 38V and 76V BMS for 3rd gen eration are interchangeable with software update The 3rd Generation BMS manages all the functions as described in the 1st Generation BMS MAF11500 MAF16860 BMS Connection 1st 2nd Gen Temperature Sensor View AA Temperature Sensor BMS Connection 3rd Gen View BB MAF12850 Figure 2 5 3...

Page 21: ...Generation BMS Connectors 38 Volt Battery Pack 76 Volt Battery Pack BMS Arrangement Table 2 4 3rd Generation BMS Connectors J1 Temperature Sensor J2A CAN BUS line Ignition J2B Feed to Devices LEM Sensor Fan Heater Internal Contactor G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 22: ...sors of different Generation BMS NOTE 1st Generation 2nd Generation and 3rd Generation LEM sensors are not interchangeable NOTE The LEM sensor has a direction of installation Care fully install the LEM sensor in correct direction MAF11510 Figure 2 8 1st Generation LEM Sensor MAF11520 Figure 2 9 2nd Generation LEM Sensor MAF12770 Figure 2 10 3rd Generation LEM Sensor MAF16870 Figure 2 11 LEM Sensor...

Page 23: ... managed by the BMS by disconnecting the battery circuit to the machine in case of failure or incorrect electrical energy limit NOTE Make sure to connect the wire correctly to internal contactor for the system to function properly Internal Contact LEM Sensor MAF11540 1st and 2nd Generation MAF12780 3rd Generation MAF11530 Figure 2 12 Internal Contactor G o t o D i s c o u n t E q u i p m e n t c o...

Page 24: ...F11550 Cell Feature Rated Voltage of each Cell 3 2V Maximum Cell Voltage 3 65V Minimum Cell Voltage 2 5V Cathode Lithium Iron Phosphate LiFePO4 Anode Graphite Capacity 90 100 150 Ah Power Pack Voltage V 48 72 83 Cell Capacity A hr 50 90 100 90 100 100 150 100 No of Cells in battery Pack 12 15 22 24 26 NOTE Cell Code serial number and capacity are stamped on side of each cell Valid on 1st and 2nd G...

Page 25: ...les 3000 NOTE Cell Code serial number and capacity are stamped on side of each cell Valid on 3rd Gen only MAF16890 Valid on 3rd Gen only Important Notes Recharge at least once per month Do not store empty Do not keep under the sun Number of cycle 3000 at 25 C DOD 100 standard reference Number of cycle 2000 at 55 C DOD 100 standard reference Self Discharge Calender life also depends on storage temp...

Page 26: ...ng princi ple used by the operator small daily charges charge only with machine completely flat par tial charges etc Refer to above diagrams 3 Another important characteristic of the lithium batteries is the number of complete charge cycle before the charging capacity decreases As shown in the diagram above the cells may charge below 80 of its capacity only after 2000 complete charging cycles 100 ...

Page 27: ...ring of the cells 1st and 2nd Generation System for cells temperature sen sor arrangement is shown below Eight temperature sensors are distributed in the battery pack near the cells to monitor the temperature The BMS activates two fans to cool down the temperature of the pack when the temperature inside the pack rises above limit MAF11580 48 Volts battery pack MAF11590 72 Volts battery pack G o t ...

Page 28: ... PROCEDURE 31215460 2 15 MAF16900 76 Volts 150 Ah battery pack MAF16910 76 Volts 100 Ah battery pack MAF16920 38 Volts 100 Ah battery pack G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 29: ... BMS activates two fan to cool down the tem perature inside the pack Refer Section 1 If everything is ok the BMS feeds the coil of the internal contactor relay so the current can go outside the battery pack In case of failure or incorrect parameters the BMS keeps the internal contactor open and the current cannot reach the inverter 2nd Generation system cells and temperature sensor arrangement are...

Page 30: ...460 2 17 Cell and Temperature Sensor Location MAF11610 Figure 2 13 48V Battery Pack 1st Generation Only MAF16900 Figure 2 14 76 Volt 150 Amp 3rd Generation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 31: ... 18 31215460 MAF11620 Figure 2 15 72V Battery Pack 1st Generation Only MAF16930 Figure 2 16 X26JP X770AJ before SN C170001340 83V 100Amp Esagon Control G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 32: ...SECTION 2 SERVICE PROCEDURE 31215460 2 19 MAF16940 Figure 2 17 X26JP X770AJ from SN C170001340 76V 100Amp TTC Control G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 33: ...SECTION 2 SERVICE PROCEDURE 2 20 31215460 MAF16950 Figure 2 18 X17JP X550AJ 48V MAF16960 Figure 2 19 X20JP X600AJ 72V G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 34: ...w minutes before the charge to heat the battery pack and reduce the charging times or charge the machine after having completed work when the battery pack is still warm It is important to store the machine with some charge remaining in the battery There will not be any problems if the battery is completely discharged but it will require longer time during charge cycle There is a self cooling syste...

Page 35: ...n the 1st generation system the fans are managed by a timer T1 shown below which is controlled by the BMS When the internal temperature is high the BMS sends sig nal to the timer coil that sends signal to the two fans for a set time After this time if temperature is still high the timer is activated again In the 2nd and 3rd generation system BMS controls the fans when necessary MAF11650 Upper Sect...

Page 36: ...23 MAF11670 BMS Figure 2 20 1st Example of BMS Wiring Interface Temperature voltage of the single cells and the system power absorption controls are highlighted G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 37: ...SECTION 2 SERVICE PROCEDURE 2 24 31215460 2 6 HEATER SYSTEM 3RD GENERATION Heater 38V MAF12880 2 Heaters 60 W each one G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 38: ...SECTION 2 SERVICE PROCEDURE 31215460 2 25 Heater 76V 100AH MAF12890 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 39: ...unction Start at 1 C or lower stop at 2 C Managed automatically by BMS From 20 C to 2 C If SOC 1 they are in any case NOTE If SOC 1 heaters will work only if BC plug is con nected MAF12900 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 40: ...n the initial phase of battery charging the BMS controls the maximum current available from the charger and afterward the current will decrease according to the cells voltage level The battery chargers have an LED with a flashing code which shows the state of charging process MAF11680 Figure 2 21 Battery Pack Charger 48 Volt Battery Pack Charger 1st 2nd Gen 38 Volt Battery Pack Charger 3rd Gen MAF...

Page 41: ...te the machine when batteries are charging in this condition if the current necessary for the movement is more than the maximum current available from the battery charger the additional energy required by the system is utilized from the battery pack to run the electric motor Battery Charging and Discharging Battery discharge condition All the cells will discharge together while machine is oper ati...

Page 42: ...ntrols the char ger to provide the maximum current as per setting and as soon as one cell reach the 3630 mV the BMS adjusts the charger to reduce the current supply MAF11720 Figure 2 26 Charging Phases Phase Recharging With Maximum Current Available or under Light Charge 1 Cells Voltage Measurement 2 Signal to activate the charger and regulate the delivery amount of current 3 Line connected to the...

Page 43: ...0 or 150 Amp only 1 V Battery Voltage 2 t Time remained on charge 3 A Actual current supplied 4 Ah Total current supplied 5 Red Light Steady On when charging 6 Green Light Blinking when Balancing Steady On when charged 7 Display G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 44: ...d with the maximum current possible Red Flashing 2nd charge step Cells under charge with reduced current Yellow Flash 3rd charge step Cells under light charge Yellow 4th charge step Balancing and Maintenance Green Red Flash Error The Battery pack is disconnected G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 45: ...t current feed to keep the cells at the same voltage level 2nd Generation BMS Algorithm Charging 2nd generation BMS tries to get all the cells to minimum 3580 mV so the perfect result is highest cell at 3630 mV Lowest cell at 3580 mV The maximum difference between the highest and the lowest cell should be 250 mV or less The last phase of the charging process is called Equaliza tion During this pha...

Page 46: ...25A for 48V battery pack 30A for 72V and 83V battery pack 18A for 38V battery pack 13A for 76V battery pack For ANSI marked machines the maximum current is set at 18A for 48V battery pack 13A for 72V and 83V battery pack 18A for 38V battery pack 13A for 76V battery pack NOTE These values are factory set but can be changed locally by means of the RamHino Tool G o t o D i s c o u n t E q u i p m e n...

Page 47: ...remote control display with the machine power ON Icon shown below is displayed on the remote control display If the machine is ON while charging the LCD display on the platform control station also shows the machine charge indicator MAF11740 MAF11760 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 48: ...tery pack while on undercar riage top frame next to the case for the 72V battery pack as shown below This indicator shows the current charge state of the Lithium ION battery pack MAF11750 48 Volt System 72 83 Volt System 38 Volt System 76 Volt System G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 49: ...SECTION 2 SERVICE PROCEDURE 2 36 31215460 MAF16990 76 volt 150 Amp 72 volt X 20JP X600AJ G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 50: ...Yellow Yellow Flash Yellow Flash 4th phase Equalization standby Yellow Flash Yellow Yellow 72Vand83VSystems 1st phase recharging with max current available Red Steady 2rd phase Cells under light charge Orange Flash 3th phase Equalization standby Green Steady 76VSystems 1st phase recharging with max current available Red Steady 2rd phase Equalization standby Green Flash 3rd phase End of charge Gree...

Page 51: ... Lead acid battery will be preserved from complete discharge DC DC Transformer The BMS is powered by the 12V auxiliary battery to ensure proper functionality even if the battery pack is completely discharged It also powers the other ECM of the platform The charging process of this Lead acid 12V battery is per formed by an electronic board DC DC which transforms the DC 38V 48V 72V 76V 83V of the ba...

Page 52: ...er system and hence one electric motor and one tandem hydraulic pump The Inverter controls the electric motor RPMs according to input received from ECM1 2 MAF11800 Table 2 6 Electric Motor Characteristics 38VBatteryPack 48VBatteryPack 72VBatteryPack 76VBatteryPack 83VBatteryPack Electric Motor 3 Phase AC Nominal Voltage 38V 48V 80V 76V 80V Power 2000 W 2000 W 3500 W 76 Volt 100 Amp 3500 W 76 Volt ...

Page 53: ...e rpm Managing the RPMs allows for optimal performance and less current or battery consumption For example while driving the motor must run at the highest RPMs while movements such as jib arm or platform rotation need requires lower RPMs Reducing the rpm saves energy and extends the opera tional autonomy of the battery NOTE On 3rd Gen it is also possible to check the motor RPMs in the menu INPUT M...

Page 54: ...rors the inverter supplies power to the external main contactor relay to close the line This contactor is connected in series with the internal contactor controlled by the BMS located inside the battery pack If the contactor is not closed while the machine is operating the movements are not possible as the electric motor cannot get power supply NOTE Inverters have the same hardware but different s...

Page 55: ...ng to the function activated by the operator To optimize the per formances and keep the movements smooth these communications are performed by a series of switches inside ECM1 2 The Inverter controls the condition of low level battery pack When the battery charge level reaches 10 of the total capacity this informa tion is provided by the BMS through CAN BUS the inverter reduces the motor rpm and r...

Page 56: ... Function Relay Number 48VBatteryPack 72V 83VBatteryPack 38V 76VBatteryPack R1 BMS Activation BMS Activation BMS Activation R2 Connection Lead acid Battery to DC DC Connection Lead acid Battery to DC DC Inverter Running Consent R3 BC Activation from BMS G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 57: ...um Battery pack CAN BUS cable to avoid too many messages in the CAN network This reduces the possibility of wrong messages The CAN Bridge Box is an opto isolator component that supplies electrical signal between two isolated circuits by using light NOTE ECM1 2 supplies power to the CAN Bridge Box If the Machine is OFF the CAN Bridge Box will not func tion MAF11870 Figure 2 38 CAN Bridge Box X700AJ...

Page 58: ...nd the system error icon disappears when the machine is restarted Some icons displayed on LCD display screen are shown below 1 Battery Under Charge The Battery Under Charge icon appears when the plug socket is connected to local electrical supply network The machine can be used in this condition 2 Battery Pack Charging Level This displayed appears when the battery pack voltage level is below 10 In...

Page 59: ...ode only then the icon battery cold is shown on the display 6 BMS Logic Discharging 1st Step Battery Level 20 Beep on Remote Control 2nd Step Battery Level 15 Low speed Only 72V 150Ah 2nd Step Battery Level 10 Extra Low Speed No 72V 150Ah 3rd Step Battery Level 4 Ultra Low speeds Only for 3rd Gen 4th Step Battery Level 0 Connect the Plugs MAF12010 MAF12020 MAF11910 G o t o D i s c o u n t E q u i ...

Page 60: ...re of the master board ECM modules BMS does not start as the supply for BMS comes from ECM modules If BMS is off it is not possible to turn on the motor as the inverter does not get any sup ply from the cells In such case connect the battery charger to the local network to start the electric motor The BMS will be switched on by the battery charger If the local network is not available the BMS can ...

Page 61: ...SECTION 2 SERVICE PROCEDURE 2 48 31215460 MAF12040 Figure 2 39 Electrical Motor Bypass G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 62: ...with a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 63: ...ne opera tion can be continued If the key icon is still displayed refer trouble failure code using the instructions below Press Button 6 on the remote control service then press button 3 errors then press button 1 prev until the below page is on display 9 The page shows the BMS Inverter and battery charger trouble codes Zero means there is no error BMS BMS trouble codes INVER Inverter trouble code...

Page 64: ...S Fault Codes 1st and 2nd Generation Battery Pack ErrorCode ErrorDescription 01 System Configuration Error 02 Unexpected Voltage 03 Unexpected Temperature 04 Overcurrent Discharge 05 Overcurrent Charge 06 Pre charge Error 07 No 12 Volt Supplies 08 No 12 Volt Supplies 09 Battery Over temperature 10 Electronics Over temperature 11 Bad Temp Sensor Auto Shut Off Mode 12 All Temp Sensor Broken 13 Broke...

Page 65: ...iationthan10mOhm in 1 second 32 0020 DISCHARGE OVER CURRENT 200A for more than 1 sec or CHARGE OVER CURRENT 120A for more than 1 sec 64 0040 NO ERROR IS MAPPED NOW 128 0080 OVER TMPERATURE BOARD TEMPERATURE 100 C 4096 1000 Despite attempts to self restore the communication loss with internal electronics devices persists for more than 10 seconds 16384 4000 ONLY for MASTER SLAVE configuration If the...

Page 66: ...to a working condition In casetheanomalypersistsreplace the inverter 26 Current Sens KO Current sensor for the motor phases is damaged Replace the inverter 27 Phase KO One of the motor phases is open Check the connection from the inverter to the motor 28 Pump Vmn Low Pump motor output is too low Check the electric motor connection 29 Pump Vmn High Pump motor output is too high Check the electric m...

Page 67: ...erter 60 Capacitor Charge Problem in the inverter Control the inverter connections and supply replace the inverter 61 High temperature Temperature rise in the inverter Allow better cooling to the inverter If the anomaly remains contact JLG 65 Motor temperat High motor temperature Stop the machine temporarily to enable motor cooling 67 Can Bus KO The inverter does not receive any information from C...

Page 68: ...verter Check the main contactor 77 Tiller Error Input mismatch between hard soft switch input and tiller input Check the CAN BUS Line connections 78 VACC not OK Usuallyitisatemporaryanomaly due to a working condition In casetheanomalypersistsreplace the inverter 79 Incorrect start Starting procedure not correct Control the electric connections Usuallyitisatemporaryanomaly due to a working conditio...

Page 69: ...e Contact JLG 96 Analog Input ProblemontheA Dconversionof uC It should be a temporary error if the problem occurs permanently replace the inverter 99 Checkup needed Contact JLG NOTE Before starting the diagnosis with fault research control the voltage level of the battery pack Table 3 3 Inverter Fault Codes ErrorCode ErrorCondition ErrorDescription CorrectiveAction G o t o D i s c o u n t E q u i ...

Page 70: ...when reading internal memory on microcontroller Battery charger stops working Contact service dept Or change product 244 Mains voltage lower than maximum operating range tolerance Battery charger won t start charging until mains voltage returns within normal operating range Make sure mains voltage is within correct operating parameters 245 Abnormal current draw in primary section Battery charger s...

Page 71: ...ction Yes A02 CAN BUS KO Trouble on CAN communication No A03 Watchdog Logic board mis working Yes A05 High battery temperature Battery temperature higher than 55ºC Temporary A07 Overcurrent Over current Temporary A08 High temperature Battery charger high temperature Temporary A09 Mismatch Voltage Battery voltage sensing error Temporary A10 Timeout Phase 1 finished for timeout Yes A11 No mains pres...

Page 72: ... the wiring diagram to check the remote control feed 3 LED on the main board are OFF Check the 12V Lead acid battery it supplies power to all the boards during the ignition If Lead acid is not OK the machine will remain off Check the voltage on the 12V switch under the key switch IF red wire to the ground has 12 Volt go to step 4 if not go to step 5 4 Red wire has 12 Volt Check the 12 Volt switch ...

Page 73: ...supply to the connections and LED are ok but the CAN BUS LED are OFF check the CAN BUS connections 9 Battery charger works ok but the battery level indicated on the display remains zero If wrench icon appears on the display as shown below go to step 10 if not go to step 17 10 Wrench icon is shown on the display Check the trouble codes push button no 6 ser vice and then no 3 errors then no 1 previ ...

Page 74: ...ger LED during the charge go to step 7 E It is not possible to charge the battery pack age at 100 even after several hours of charge If after connecting the 110 220V power cable the light on the battery charger is red after two minutes go to step 6 if not go to step 20 20 Battery charger works correctly but the battery level never reaches 100 Connect the 120 220V power cable and keep it connected ...

Page 75: ...her However it can discharge the highest cell con necting it to a resistance there is one resistance in BMS for every cell When a new cell reaches 3630 mV the BMS will connect it to its resistance so at the end all the cells will be charged at the same level and have the same performances Normally a fine battery pack should have at the end of the equalization phase the value Delta mV less than 50 ...

Page 76: ... If the light on battery charger is red go to step 6 27 Light on the battery charger is flashing red green two minutes after connecting the power cable If the light on battery charger flashes red green go to step 7 I Plug icon on the display interchanges continu ally with the battery icon while charging Check the value battery in the INPUT menu press button number 6 service press 1 input and 1 pre...

Page 77: ...Lead acid battery to fuse F6 Lead acid battery feed connector R1 2 ways connector B Battery package level is zero even after the charge Check the value in the INPUT menu press button number 6 service then press 1 input then 1 previous Press button number 9 Esc to go back If external electrical power is available connect the 110 220V power cable and check the bat tery charger light after two minute...

Page 78: ...If the fuse F4 and its line are ok check fuse F160 then check if fuse F160 has 48 Volt to the ground If fuse F160 shows 48 Volt go to step 12 if not go to step 13 12 Fuse 160 A has 48 Volt Check the Inverter connections 13 Fuse 160A does not show 48 Volt If Fuse 160A does not receive supply BMS can be OFF so the internal contactor is also OFF go to step 7 If everything is ok check the internal con...

Page 79: ...l hours If failure remains go to step 21 21 Battery charger lamp is yellow for many hours but the battery pack level never reached 100 of charge Connect the RamHino tool to the machine and choose the accurate LITHIUM model on window menu Machine as shown below At the end of Battery Charge values as shown in above image should shown on the display a Delta mV it is the difference between the highest...

Page 80: ...ed at the same level and have the same performances Usually a fine battery pack should have at the end of the equalization phase the value Delta mV less than 50 mV and average value of approximately 3600 mV With a resulting Delta mV value more than 150 mV and the highest cell already reached 3630 mV record the voltage and the number of the highest cells Leave the machine under charge overnight If ...

Page 81: ...able If the light on battery charger is red go to step 6 27 Light on the battery charger is flashing red green two minutes after connecting the power cable If the light on battery charger flashes red green go to step 7 I Plug icon on the display interchanges continu ally with the battery icon while charging Check the value battery in the INPUT menu press button number 6 service press 1 input and 1...

Page 82: ...eck the connection of the wire 1 12 from the key switch to the pin B1 in the master board 5 Red wire does not have 12 Volt Check fuse F6 then check the feed from 12 Volt Lead acid battery to fuse F6 Lead acid battery feed connector R1 2 ways connector B Battery package level is zero even after the charge Check the value in the INPUT menu press button number 6 service then press 1 input then 1 prev...

Page 83: ...tly but the battery level indicated on the display remains zero If wrench icon appears on the display as shown below go to step 10 if not go to step 17 10 Wrench icon appears on the display Check the trouble codes push button no 6 ser vice and then no 3 errors then no 1 previ ous If trouble code 80 is shown on the inverter go to step 11 if not go to step 14 11 Inverter trouble code is number 80 Ch...

Page 84: ...ger LED during the charge go to step 7 E It is not possible to charge the battery package at 100 even after several hours of charge If after connecting the 110 220V power cable the light on the battery charger is red after two minutes go to step 6 if not go to step 20 20 Battery charger works correctly but the battery level never reaches 100 Connect the 120 220V power cable and keep it connected t...

Page 85: ...ogether However it can discharge the highest cell con necting it to a resistance there is one resistance in BMS for every cell When a new cell reaches 3630 mV the BMS will connect it to its resistance so at the end all the cells will be charged at the same level and have the same performances Normally a fine battery pack should have at the end of the equalization phase the value Delta mV less than...

Page 86: ...charger is flashing red green two minutes after connecting the power cable If the light on battery charger flashes red green go to step 7 I Plug icon on the display interchanges intermit tently with the battery icon while charging Check the value battery in the INPUT menu press button number 6 service press 1 input and 1 previous Press 9 Esc to go back If during charge the battery level is changin...

Page 87: ...the connection of the wire OR0400 or 1 12 from the key switch to the pin B1 in the master board 5 Red wire does not have 12 Volt Check fuse F6 then check the feed from 12 Volt Lead acid battery to fuse F6 Lead acid battery feed connector R1 2 ways connector B Battery package level is zero even after the charge Check the value in the INPUT menu press button number 6 service then press 1 input then ...

Page 88: ...r works ok but the battery level indicated on the display remains zero If wrench icon appears on the display as shown below go to step 10 if not go to step 17 10 Wrench icon appears on the display Check the trouble codes push button no 6 ser vice and then no 3 errors then no 1 previ ous If trouble code 80 is shown on the inverter go to step 11 if not go to step 14 11 Inverter trouble code is numbe...

Page 89: ...uring the charge go to step 7 E It is not possible to charge the battery package at 100 even after several hours of charge If after connecting the 110 220V power cable the light on the battery charger is red after two minutes go to step 6 if not go to step 20 20 Battery charger works correctly but the battery level never reaches 100 Connect the 120 220V power cable and keep it connected to the mac...

Page 90: ...ogether However it can discharge the highest cell con necting it to a resistance there is one resistance in BMS for every cell When a new cell reaches 3630 mV the BMS will connect it to its resistance so at the end all the cells will be charged at the same level and have the same performances Normally a fine battery pack should have at the end of the equalization phase the value Delta mV less than...

Page 91: ...ay interchanges intermit tently with the battery icon while charging Check the value battery in the INPUT menu press button number 6 service press 1 input and 1 previous Press 9 Esc to go back If during charge the battery level is changing irregularly from 100 to another value go to step 21 If during charge the battery level is not 100 leave the machine under charge over night L Battery package le...

Page 92: ...har ger is connected and the BMS is ON the RamHino Lithium page can be seen even if the machine is OFF For X23J machine the battery Pack has a specific CAN BUS cable for the Lithium main components BMS Inverter Battery Charger this CAN BUS Line is connected to the platform CAN BUS Line by a CAN Bridge Box CAN Bridge Box is switched On by the main board ECM1 2 so Ram Hino connection by the emergenc...

Page 93: ...AJ Connect Pack Can device to the cable of remote control at the ground port on the side For modelsX17JP X500AJ X20JP X600AJ X26JP and X770AJ Connect the Peak Can device to the port of the remote control at the ground port on the side MAF12170 MAF12180 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 94: ... Run the RAMHINO Flash Program through the icon on desktop Below screen will appear Select the applicable machine model from the win dow menu Machine Click on INITIALIZE button to activate PC laptop machine communication MAF12190 Window MENU MACHINE INITIALIZE MAF12200 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 95: ...rs binary lan guage as shown below If there is no communication between PC laptop and machine system data will not be displayed on the screen In such case do the following a Check the USB port on PC laptop Try differ ent ports b Restart the RamHino program c For X17J model only check the correct wire connections Pins 2 and 6 MAF12210 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y ...

Page 96: ...no Lithium page The only difference is the pack drawing The Cell number and temperature sensor location are shown on 48V bat tery pack page while cell number and temperature sensor position are shown on 72 83V battery pack page Lithium Battery System Page MAF12220 MAF12230 Figure 3 1 48V Battery System page 1st and 2nd Generation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u ...

Page 97: ...AULT CODES 31215460 3 35 MAF12240 Figure 3 2 72 83V Battery System page 1st and 2nd Generation MAF12830 Figure 3 3 38V Battery System page 3rd Generation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 98: ...ery pack 3 3 X 15 72 6V on 72V battery pack 3 3 X 22 79 2V on 76V battery pack 3 3 24 and about 85 8V on 83V battery pack 3 3 26 To check the minimum real value of voltage the battery pack must be under discharge An arm or one or more stabilizer can be moved for some time so that there is a voltage drop and the voltage value measured is real To check the maximum value of voltage the battery pack m...

Page 99: ...ack discharge If there is no sign the current is going inside the pack charge During charge if the machine is not moving Current A value should be close to the DMCC A value as the current required to the battery charger is almost the same as the current going inside the battery pack For example if DMCC A value is 25 Amp and the Current A value is 1 5 Amp the battery charger is disconnected or one ...

Page 100: ...h cell is the highest one completely discharge and recharge the system and check again 2 Lowest at It is the voltage at the lowest cell The number of the corresponding cell is indi cated on side During the charge As the lithium cells do not have the same characteristics at 100 even when they are charged with the same current level it is possible that one cell reaches the max imum charge level quic...

Page 101: ... charge the highest cell is still the same without increase in the average value there is a failure because the BMS is not able to discharge that specific cell In this case it is seen that SOC never reaches 99 100 Delta mV is more than 250 mV Average voltage does not reach 3580 3600 mV Highest cell is the same After every charge of battery pack final SOC level is lower than the charge earlier If a...

Page 102: ...he internal temperature reaches 70 C In this case or if a sensor detects a high temperature a specific failure code is shown in the window Emergency Error Code Fifth Group Cell Resistance mOhm only for 1st Generation BMS 1 Lowest at It is the lowest resistance of the cells The cell number is showed on side 2 Highest at It is the highest resistance of the cells The cell number is showed on side 3 A...

Page 103: ...en replacing BMS in case of failure For 2nd generation BMS it is UNKNOW Eighth Group BMS Status only for 1st Genera tion BMS The following parameters are internal to the BMS hence cannot be controlled However their status is helpful when replacing BMS in case of failure 1 Power Control Microcontroller supply ON OFF 2 Heating Control Heating Control ON OFF 3 Overcharge 2nd prot Secondary Protection...

Page 104: ...the Log file will be saved Click on Save to start the recording Click the icon to stop recording data The file gener ated should be opened in Excel format and the Lithium battery pack data stored every second can be visualized with the time hhmmss date is already shown in the default name of the file LOG file is useful for the diagnostic of the Lithium system MAF12350 G o t o D i s c o u n t E q u...

Page 105: ...SECTION 3 TROUBLESHOOTING AND FAULT CODES 31215460 3 43 DMCC A and Cell Capacity Setting MAF12360 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

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