Let me start off by saying that I think I've got a bad motor controller, but they are very expensive, and I understand that I may be missing something.
First the symptoms:
All lift, lower, swing and rotate functions work. As does the steering. Forward traverse works well. Reverse is the problem. When the joy stick is moved in the reverse direction, you will hear a click from one of the contactors, the brakes do not release, and the controller immediately flashes the #2 code "procedure fault".
What I've done:
1. I removed the wire #8 (+48VDC Forward) going into the controller to remove the possibility of selecting both directions at once. According to the manual this is one of the primary causes of the procedure fault..... reverse still didn't work (forward didn't either, but I think we know why ;).
2. I swapped the #8 and #11 wires (Command fwd and rev) at the controller. Now when you ask the lift to go in reverse, it goes forward. When you ask it to go forward you get the procedure fault. to my way of thinking this confirms the controls are good from the stick to the controller for both directions.
3. With the #8 and #11 Wires still reversed, I now swapped the #15 and #17 wires (Drive fwd and drive rev contactor wires). Oh, btw, I also took care not to disturb the wires that go from the contactors to the tach Isolation card to ground the brake (pins 8 & 9 on the tach card). This was just in case one of the two isolation diodes might be shorted. Now when you ask it to go in reverse it does indeed reverse, and when you ask it to go in forward you get the procedure fault. This seems to indicate that the reverse power circuit is functioning properly.
I realize that I still haven't ruled out that one of the lift functions might be coming active but I would think that would cause problems in the other direction. It seems to me that by swapping the controls in, and output out, I have proven everything around the controller works, and all that is left is the controller.
Have I missed something? Any thoughts would be greatly appreciated.
Thanks!
Ethos
First the symptoms:
All lift, lower, swing and rotate functions work. As does the steering. Forward traverse works well. Reverse is the problem. When the joy stick is moved in the reverse direction, you will hear a click from one of the contactors, the brakes do not release, and the controller immediately flashes the #2 code "procedure fault".
What I've done:
1. I removed the wire #8 (+48VDC Forward) going into the controller to remove the possibility of selecting both directions at once. According to the manual this is one of the primary causes of the procedure fault..... reverse still didn't work (forward didn't either, but I think we know why ;).
2. I swapped the #8 and #11 wires (Command fwd and rev) at the controller. Now when you ask the lift to go in reverse, it goes forward. When you ask it to go forward you get the procedure fault. to my way of thinking this confirms the controls are good from the stick to the controller for both directions.
3. With the #8 and #11 Wires still reversed, I now swapped the #15 and #17 wires (Drive fwd and drive rev contactor wires). Oh, btw, I also took care not to disturb the wires that go from the contactors to the tach Isolation card to ground the brake (pins 8 & 9 on the tach card). This was just in case one of the two isolation diodes might be shorted. Now when you ask it to go in reverse it does indeed reverse, and when you ask it to go in forward you get the procedure fault. This seems to indicate that the reverse power circuit is functioning properly.
I realize that I still haven't ruled out that one of the lift functions might be coming active but I would think that would cause problems in the other direction. It seems to me that by swapping the controls in, and output out, I have proven everything around the controller works, and all that is left is the controller.
Have I missed something? Any thoughts would be greatly appreciated.
Thanks!
Ethos
JLG 40E no Reverse.... Anyone got any advice
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