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jlg 1930es wont power up

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Brad Hansen

Member
Joined
May 21, 2018
Messages
14
Location
Houston, TX
2006 jlg 1930es lift. it was working fine when i parked it about 4 months ago in my workshop on clean and dry location. Tried to move it yesterday, turned key on and made sure both emergency switches 'out' (run position). Lift was completely dead-no lights, no horn, battery level lights, no solenoids clicking, nothing. So I thought batteries were completely dead maybe from some parasitic drain even though i had charged them completely when I parked it last. Plugged in the charger cord to extension cord and charging lights came on the jlg ground controller box, but no other sounds or noises when key turned on. This morning green charging light showed charging complete. Again turned key on and lift still completely dead. No solenoid noises, no lights, etc., no indication of power at ground control or platform control. Red safety buttons both on platform and carriage are in correct position. Checked battery voltage at power cables coming from the 4 batteries, 26.4 volts. Its like there is no power going to anything. I cant access the pump or where i think the solenoid would be located on the pump because the platform is down and I cant see/reach it. Where do i go from here?
 
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M

Moonlite

Senior Member
Joined
Nov 11, 2013
Messages
514
Location
Texas
First check battery connections. Make sure the red wires are connected to the main positive terminal. Also pull the cover off the power module ( between the steer tires) and see if you have a light on. They go to sleep (as jlg termed it) you can wake them up but you’ll need an analyzer to do it. Also check the breaker on the ground control box.
 
B

Brad Hansen

Member
Joined
May 21, 2018
Messages
14
Location
Houston, TX
Moonlite said:
First check battery connections. Make sure the red wires are connected to the main positive terminal. Also pull the cover off the power module ( between the steer tires) and see if you have a light on. They go to sleep (as jlg termed it) you can wake them up but you’ll need an analyzer to do it. Also check the breaker on the ground control box.
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Older model Sevcon power module has no lights to display any codes, etc. Breaker at control box is not popped. Battery connections good, have 24.5volts at contactor post. Jumped across contactor solenoid posts and still no power to pump, lift, drive wheels, control box lights or any sign of life. I did find a galvanized nail may have shorted across power module posts M1 and M2. (see photo) Could this have blown out power module?
 

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B

Brad Hansen

Member
Joined
May 21, 2018
Messages
14
Location
Houston, TX
correction to last post, upon further examination there is a green lensed light on the power module, it is not lit. I have never witnessed it lit or not before since i have never had the power module cover off before.
 
M

Moonlite

Senior Member
Joined
Nov 11, 2013
Messages
514
Location
Texas
Jlg has their manuals online. You should have the green light lit on the power module. The manuals have wiring schematics. Again make sure the small wires on the main positive post are making contact and not corroded off.
 
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tool_king

Senior Member
Joined
Mar 29, 2010
Messages
2,151
Location
new jersey
Occupation
road mechanic owner
Brad Hansen said:
2006 jlg 1930es lift. it was working fine when i parked it about 4 months ago in my workshop on clean and dry location. Tried to move it yesterday, turned key on and made sure both emergency switches 'out' (run position). Lift was completely dead-no lights, no horn, battery level lights, no solenoids clicking, nothing. So I thought batteries were completely dead maybe from some parasitic drain even though i had charged them completely when I parked it last. Plugged in the charger cord to extension cord and charging lights came on the jlg ground controller box, but no other sounds or noises when key turned on. This morning green charging light showed charging complete. Again turned key on and lift still completely dead. No solenoid noises, no lights, etc., no indication of power at ground control or platform control. Red safety buttons both on platform and carriage are in correct position. Checked battery voltage at power cables coming from the 4 batteries, 26.4 volts. Its like there is no power going to anything. I cant access the pump or where i think the solenoid would be located on the pump because the platform is down and I cant see/reach it. Where do i go from here?
Click to expand...
There a small red wire that goes from the battery positive to lower control box .If that wire is broken it will not power up .It usely get broken right top of the batties on the right side of the machine.
Do not unbolt lower control box unless you have the jlg tool .It will cause the bx to need calibration .
 
B

Brad Hansen

Member
Joined
May 21, 2018
Messages
14
Location
Houston, TX
Yes, that was it! The wire had been corroded by battery acid not at the terminal, but about 1 foot from positive battery cable. So it was completely hidden and remained unnoticed until I peeled way back the split plastic wire loom that covers the wiring. The insulation was bulging in 3 separate areas along a 8 inch section of wire. Upon cutting open the red insulation, the copper wire inside had been completely transformed into blue/green copper sulfate from the acid. I was getting 24 volts to the ground control box when unit was powered off (no load) but voltage dropped down to less than 6 volts when tried to power on the unit. Replaced bad section of wire and lift is operational again. FYI, maybe I got lucky with removing the control box (more than once) but it works fine upon reassembly (didn't require recalibration). Before this, I had checked all connections at the batteries as Moonlite had suggested but they were all fine but problem wire remained concealed under the black plastic wire loom. I had almost convinced myself the ground control circuit board was bad until I called JLG support and they helped me isolate the problem via multimeter testing.
 
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tool_king

Senior Member
Joined
Mar 29, 2010
Messages
2,151
Location
new jersey
Occupation
road mechanic owner
Brad Hansen said:
Yes, that was it! The wire had been corroded by battery acid not at the terminal, but about 1 foot from positive battery cable. So it was completely hidden and remained unnoticed until I peeled way back the split plastic wire loom that covers the wiring. The insulation was bulging in 3 separate areas along a 8 inch section of wire. Upon cutting open the red insulation, the copper wire inside had been completely transformed into blue/green copper sulfate from the acid. I was getting 24 volts to the ground control box when unit was powered off (no load) but voltage dropped down to less than 6 volts when tried to power on the unit. Replaced bad section of wire and lift is operational again. FYI, maybe I got lucky with removing the control box (more than once) but it works fine upon reassembly (didn't require recalibration). Before this, I had checked all connections at the batteries as Moonlite had suggested but they were all fine but problem wire remained concealed under the black plastic wire loom. I had almost convinced myself the ground control circuit board was bad until I called JLG support and they helped me isolate the problem via multimeter testing.
Click to expand...
Check your lift up functions all the way up .Your tilt sensor is in the lower control box .
 
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