JLG X390AJ-X14J Owner's manual

Supplement Manual
Models
X390AJ-X14J
X550AJ-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
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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, Bennar Newman, Haulotte, Ditch Runner, Menegotti,
Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Barreto, EZ Trench, Bil-
Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD,
Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter,
Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK,
Rol-Air, Small Line, Wanco, Yanmar

Models 48V Gen1 48V Gen 2 72V Gen1 72V Gen 2
X390AJ-X14J Prior to SN
C170000323
SN 170000350
to Present
X550AJ-X19J Prior to SN
C170000319
SN C170000332
to Present
X700AJ-X23J Prior to SN
C170000340
SN C170000352
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
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
31215460 A-1
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
GENERAL
These instructions include the technical information of the
Lithium ION system, which is one of the power system
configurations on JLG Compact Crawler Booms (CCB).
NOTICE
READ THESE INSTRUCTIONS AND OPERATION MAINTENANCE OF THE
MACHINE CAREFULLY.
•IN CASE OF CELL FAILURE, DO NOT OPEN THE BAT-
TERY COMPARTMENT.
•IF THE BATTERY COMPARTMENT TEMPERATURE IS
HIGH, OPEN THE BATTERY COMPARTMENT CARE-
FULLY TO COOL THE CELLS. WAIT UNTIL THE COM-
PARTMENT IS COOLED DOWN TO AMBIENT
TEMPERATURE.
•DO NOT OPEN THE BATTERY COMPARTMENT IF THE
TEMPERATURE IN THE COMPARTMENT IS TOO HIGH.
THERE IS A RISK OF EXPLOSION OR EXPOSURE TO
HAZARDOUS SUBSTANCES.
•WEAR APPROPRIATE PROTECTIVE EQUIPMENT ON
HANDS, FEET, EYES AND BODY WHILE WORKING ON
BATTERIES MAINTENANCE AND BATTERY COMPART-
MENT.
NOTICE
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 motor which
receives power through the Lithium ION battery pack.
The Lithium ION Battery pack integrates a system to con-
trol the RPM of the electrical motor, to supply sufficient
amount of oil flow to the hydraulic system, to recharge the
batteries, and to keep all components functional.
The Lithium ION Battery pack system is controlled by a
device called Battery Management System (BMS). All com-
ponent or functions are activated by the BMS. At the start
of the machine, the 12 volts Lead-acid Battery switch ON
the BMS through the ECM1-2. If there is no fault, the BMS
gets supply from Lithium ION Battery pack.
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A-2 31215460
REVISON LOG
Original Issue A - October 14, 2019
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31215460 i
TABLE OF CONTENTS
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 BATTERY PACK CONFIGURATION LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SECTION 2 - SERVICE PROCEDURE
2.1 12V DC POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 OPERATION OF THE POWER PACK COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 BATTERY MANAGEMENT SYSTEM (BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
48V/72V Systems with 1st Generation BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
BMS Connectors (1st Generation BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
48V Systems with 2nd Generation BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
72V/83V with 2nd Generation BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
BMS Connectors (2nd Generation BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Temperature Sensor Test - 2nd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
38V/76V with 3rd Generation BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
BMS Connectors (3rd Generation BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
LEM Sensor and Internal Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4 LITHIUM BATTERY CELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Characteristics of Lithium Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
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 Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Phase - Equalization or Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Equalization or Standby Algorithm Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Battery Charging - Lithium ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Lithium ION Charge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Lead-Acid Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
DC-DC Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
RPM Speed Sensor and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Inverter and Main Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.8 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
CAN BUS Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
CAN Bridge Box (X700AJ and X23J only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Lithium Battery Condition Display Icon and Warning Purposes . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.9 EMERGENCY ELECTRIC MOTOR OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
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ii 31215460
TABLE OF CONTENTS
SECTION 3 - TROUBLESHOOTING AND FAULT CODES
3.1 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 BATTERY SYSTEM TROUBLESHOOTING (1ST & 2ND GEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
48V Battery Pack (Prior to SN C170000330). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
48V Battery Pack (SN C170000330 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
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31215460 iv
LIST OF FIGURES
1-1. 48V Pack Upper Section (1st Generation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2. 48V Pack Upper Section (2nd Generation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-3. 72V Pack Upper Section (1st Generation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4. 72V/83V Pack Upper Section (2nd Generation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-5. 38V Pack Upper Section (3rd Generation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-6. 76V Pack Upper Section (3rd Generation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2-1. 48 Volt BMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2. Single Electronic Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3. BMS A (Card Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-4. BMS B (Card Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-5. 38 Volt BMS - 3rd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-6. 76 Volt BMS - 3rd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-7. 3rd Generation BMS Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-8. 1st Generation LEM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-9. 2nd Generation LEM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-10. 3rd Generation LEM Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11. LEM Sensor wires connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-12. Internal Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-13. 48V Battery Pack - 1st Generation Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-14. 76 Volt 150 Amp - 3rd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-15. 72V Battery Pack - 1st Generation Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-16. X26JP - X770AJ before SN C170001340 83V 100Amp (Esagon Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-17. X26JP - X770AJ from 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 150 Amp only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-28. DC-DC for 38V/48V Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-29. DC-DC for 72V/76V/83V Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-30. Inverter - 38V/48V Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2-31. Inverter - 38V/48V/76V RPM Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2-32. Inverter - Emergency Motor 38V/48V/76V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2-33. Inverter - 72V/83V/76V 100Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2-34. Inverter - 72V/76V/83V Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2-35. External Main Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-36. Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2-37. Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2-38. CAN Bridge Box (X700AJ and X23J only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2-39. Electrical Motor Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
3-1. 48V Battery System page - 1st and 2nd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-2. 72/83V Battery System page - 1st and 2nd Generation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-3. 38V Battery System page - 3rd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
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vi 31215460
LIST OF TABLES
1-1 Lithium Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Cell Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Battery Pack Component Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-4 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2-1 1st Generation BMS Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-2 Internal Connector Identification on BMS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 2nd Generation BMS Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-4 3rd Generation BMS Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
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
3-7 BMS Current Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
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SECTION 1 - SPECIFICATIONS
31215460 1-1
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES
Table 1-1. Lithium Systems
Model Battery Pack Machine Arrangement
X390AJ-X14J
48V-15Cells
Refer inside cover for serial break information
X500AJ-X17JP
X550AJ-X19J
X700AJ-X23J 72V-22Cells
X600AJ-X20JP 72V -22 Cells
X770AJ-X26JP 83V -26 Cells
X770AJ-X26JP 76V-24CellsPair
X370AJ-X13JP
38V-12CellsPair
X430AJ-X15JP
X1000AJ-X33JP 76V -24 Cells,Trio
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/83 V 38/76V
MachineSystemVoltage 12V
DOD(Depth of Discharge) 80% 90%
NominalVoltage 3.2V
MaximumVoltage 3.65V X26JP-X770AJ
X33JP-X1000AJ
MinimumVoltage 2.5Volt
MaximumDischargeCurrent
150A(<10s)
100A(cont)
50A(cont)
NoofCycles ~2000 ~3000
Cathode LithiumIronPhosphate(LiFePO4)
Anode Graphite
MemoryEffect No
*Reducedto3.5Voltduetothesizeofdual charge(120V-220V)84.5V
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SECTION 1 - SPECIFICATIONS
1-2 31215460
1.2 BATTERY PACK CONFIGURATION LAYOUT
MAF11320
Figure 1-1. 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)
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SECTION 1 - SPECIFICATIONS
31215460 1-3
MAF11360
Figure 1-5. 38V Pack Upper Section (3rd Generation)
MAF11370
Figure 1-6. 76V Pack Upper Section (3rd Generation)
Table 1-3. Battery Pack Component Identification
BC Battery Charger
BMS Battery Management System
CAN BridgeBox CANBUSLinesBridge(X23J-X700AJonly)
DC-DC ElectronicCurrentTransformer, from38/48/72/76/83 VoltDCto13.5Volt
FNo FuseNumber Identification
INV Inverter
Led BatteryChargerLamp
MR External Main Conductor
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
• 72V - 3 Phase/2500 Watt
• 76V - 3 Phase/2500 Watt
• 83V - 3 Phase/3500 Watt
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SECTION 2 - SERVICE PROCEDURE
31215460 2-1
SECTION 2. SERVICE PROCEDURE
2.1 12V DC POWER DISTRIBUTION
The 12V power distribution system provides the electrical
power required to operate the machine’s Electronic con-
trol modules (ECM), solenoid valves and lights. In Lithium
ION 2nd Generation BMS powered machines, it also pow-
ers the battery management system (BMS) and Lithium
ION system relays and contactors. In engine powered
machines, the 12V power distribution system powers the
glow plugs in diesel engines and the starter motor in die-
sel and gasoline engines. The 12V Power distribution sys-
tem includes the following components:
•12 Volt Lead-acid battery
•12 Volt battery cutouts
•12 Volt battery fuses
•Machine master controller (ECM1 and ECM2)
•Load Cell Board (ECM3)
•Reduced Stabilization Control Board (ECM4) X770AJ/
X26JP only
•Battery management system (BMS)
•Start relay
•Starter
•Glow plug relay
•Glow plugs
•Generator
The 12V Lead-acid battery provides the power to the
machine electronic control module (ECM) in the machine
until the engine 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 battery,
provides 12V electrical power for the machine compo-
nents. It also recharges the battery.
When the machine’s Lithium ION battery system is charg-
ing the DC-DC converter continues to recharge the 12V
Lead-acid battery.
If the Lead-acid battery is completely discharged, the
main controller and the BMS cannot be powered and
machine cannot start. To avoid this situation, if the Lith-
ium ION battery ON-OFF key switch is left on, and the volt-
age level of the Lithium ION battery pack is less than 20%,
the master controller will turn off the system if no machine
movements are performed for one hour.
Even if the operator leaves the Lithium ION battery ON-
OFF key switch in ON position, the Lead-acid battery will
be preserved from complete discharge.
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SECTION 2 - SERVICE PROCEDURE
2-2 31215460
2.2 OPERATION OF THE POWER PACK COMPONENTS
Theory of Operation
Switching ON the dual contact key switch (C) directs indi-
vidual contact with the 12V power from the Lead-acid bat-
tery (D) to power-up the ground module ECM1-2 (B), while
the other contact (38-48-72-76-83V) activates the inverter
contactor (N). The ground module ECM1-2 (B) power-up
the BMS (A) and the BMS (A) carries on the control of the
power pack system.
The BMS (A) monitoring the cells, opens/closes the inter-
nal contactor (L), manages the charge of the Lead-acid
battery (D) through the Transformer DC-DC (F) and switch
ON the inverter (N). The Inverter will close the external
contactor (M) when required to receive power to 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) and coming OUT (to electrical motor or the DC-
DC transformer). The BMS measures the total current (IN –
OUT) through the module LEM. (I).
If fault code occurs, the BMS keeps the internal contactor
(L) open and power is not available for the system. If a
fault is present, the Inverter (N) keeps the external contac-
tor (M) open, so power is not available for the electrical
motor.
MAF11410
LEAD-ACID
Lithium Battery
Pack
Lithium Battery
Charger AC-DC
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SECTION 2 - SERVICE PROCEDURE
31215460 2-3
2.3 BATTERY MANAGEMENT SYSTEM (BMS)
The Battery Management System (BMS) is the electronic
device which constantly monitors the state of the LiFePO4
cells and their best possible operation.
The main functions of the BMS are:
•Check the Voltage of every cell
•Check the Battery Pack Current in/out
•Check the Battery Pack temperature
•Manage the Battery charge
•Equalize the cell on final charge stage
•Control the cooling system in case of high tempera-
ture
•Manage 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
cells, so 2 of these boards are used on both batteries packs
(48 or 72V). The electric cell connections are shown in the
wiring diagrams.
MAF11420
Monitoring board 2
Monitoring board 1
Control board
Power board
MAF11430
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SECTION 2 - SERVICE PROCEDURE
2-4 31215460
BMS Connectors (1st Generation BMS)
MAF11440
Table 2-1. 1st Generation 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
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SECTION 2 - SERVICE PROCEDURE
31215460 2-5
48V Systems with 2nd Generation BMS
The 2nd Generation BMS can be arranged with one or two
electronic cards. The 48V 2nd Generation BMS manages all
the functions as described in the 1st Generation BMS.
72V/83V with 2nd Generation BMS
The 72V and 83V BMS is composed of two electronic cards,
positioned one above the other in the same case, BMS A
on top and BMS B on bottom side. Each electronic card
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
J10 CAN BUS
MAF11450
Figure 2-1. 48 Volt BMS
MAF11460
Figure 2-2. Single Electronic Card
MAF11470
Figure 2-3. BMS A (Card Upper)
MAF11480
Figure 2-4. BMS B (Card Lower)
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SECTION 2 - SERVICE PROCEDURE
2-6 31215460
BMS Connectors (2nd Generation BMS)
On 2nd Generation BMS, the resistances to discharge the
cells are located on the cage heating area, while 4 temper-
ature sensors are placed on the same section to monitor
the cage temperature. With temperatures above 70°C the
BMS opens the internal battery contact to avoid overheat-
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 and fans
J8 Current sensor socket (LEM)
J9 BMS feed
J10 CAN BUS socket
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SECTION 2 - SERVICE PROCEDURE
31215460 2-7
Temperature Sensor Test - 2nd Generation
1. Disconnect all temperature sensor connectors
(J1, J2, J3) from the BMS.
2. Check voltage between negative terminal and
sensor pin on connectors
a. If V=0: OK
b. If V≠0: Bad Insulation
3. Check sensor resistance values
10000 Ohm at 77°F (25°C)
15000 Ohm at 59°F (15°C)
38V/76V with 3rd 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. 38 Volt BMS - 3rd Generation
MAF12860
Figure 2-6. 76 Volt BMS - 3rd Generation
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