Troubleshooting JLG 40 RTS Issues: A Comprehensive Guide

[MikePhua]

The JLG 40 RTS is a robust and versatile rough terrain scissor lift, designed for various applications in construction, maintenance, and other demanding industries. However, like all machinery, it may occasionally encounter issues that affect its performance and reliability. Addressing these issues promptly is essential to ensure optimal performance, safety, and longevity of the equipment. In this article, we will explore common problems with the JLG 40 RTS, their potential causes, and solutions.
Understanding the JLG 40 RTS
The JLG 40 RTS is a rough terrain scissor lift that offers the flexibility to work in various environments, from construction sites to outdoor maintenance projects. This machine is equipped with features that allow it to traverse rough terrain, reach heights of up to 40 feet, and provide a stable work platform for workers at height.
Common Problems with the JLG 40 RTS
Owners and operators of the JLG 40 RTS occasionally encounter a range of issues. Some problems are straightforward and can be resolved quickly, while others may require more in-depth troubleshooting and repairs. Below are some of the most common issues reported with the JLG 40 RTS:
1. Power and Electrical Failures
One of the most frustrating issues is when the scissor lift fails to power on or operate normally due to electrical problems. This can manifest as a complete lack of power, malfunctioning controls, or intermittent operation.
Potential Causes:

• Dead or faulty batteries: Batteries are the most common cause of power failures. If the batteries are not charged correctly or are old, the machine may fail to operate.
  
• Blown fuses: Fuses protect the electrical system from power surges. A blown fuse may prevent the lift from functioning.
  
• Loose or damaged connections: Loose or corroded wiring connections can interrupt power flow to critical components.
  
• Faulty solenoid: The solenoid plays a vital role in controlling the lift's electrical system. A malfunctioning solenoid can cause the lift to fail to start or function improperly.
  

Solutions:

• Check and charge the batteries: Always ensure that the batteries are charged and that the terminals are clean and free from corrosion. If the batteries are old or damaged, consider replacing them.
  
• Inspect fuses: Check all fuses in the system, and replace any that are blown. Always use the correct amperage when replacing fuses.
  
• Examine wiring and connections: Inspect all electrical connections for corrosion, loose wiring, or signs of damage. Tighten or replace connections as needed.
  
• Test the solenoid: If you suspect an issue with the solenoid, it can be tested with a multimeter to check for proper function. Replace the solenoid if necessary.
  

2. Hydraulic Issues
Hydraulic problems are common with many lift systems, and the JLG 40 RTS is no exception. If the machine's lift, steering, or drive functions become sluggish or fail completely, it may be due to a hydraulic issue.
Potential Causes:

• Low hydraulic fluid: Low levels of hydraulic fluid can cause a variety of problems, such as slow movements or inability to raise the platform.
  
• Contaminated hydraulic fluid: Dirty or contaminated fluid can lead to poor performance and potential damage to the hydraulic pump and valves.
  
• Faulty hydraulic pump or valve: A malfunctioning hydraulic pump or valve can prevent the lift from operating correctly.
  
• Leaks in hydraulic lines: Leaks in the hydraulic lines or seals can result in a loss of pressure and cause the lift to fail.
  

Solutions:

• Check hydraulic fluid levels: Regularly inspect the hydraulic fluid level and top it up as needed with the appropriate fluid type recommended by the manufacturer.
  
• Replace contaminated fluid: If the fluid appears dirty or has a burnt smell, it’s essential to drain the system, clean it, and refill with fresh hydraulic fluid.
  
• Inspect the hydraulic pump and valves: Check the hydraulic pump for signs of wear or damage. If the pump is not functioning properly, it may need to be replaced. Similarly, check valves for blockage or malfunction.
  
• Fix hydraulic leaks: Inspect all hydraulic hoses, seals, and fittings for leaks. Replace any damaged or worn hoses and seals to prevent further leakage.
  

3. Faulty Lift/Drive System
The lift and drive system of the JLG 40 RTS is essential for smooth operation. Problems with these systems can lead to slow or jerky movements or, in the worst case, complete failure to lift or move.
Potential Causes:

• Motor or drive system failure: A malfunctioning motor or drive system can lead to sluggish or unresponsive movements.
  
• Blocked or damaged hydraulic lines: If the hydraulic lines are blocked or damaged, it can prevent the lift and drive system from operating effectively.
  
• Worn or damaged bearings: Worn bearings in the lift or drive system can lead to excessive friction, reducing the efficiency of the lift.
  
• Improper calibration: Sometimes, the lift system may need to be recalibrated, especially after significant repairs or maintenance.
  

Solutions:

• Test the drive motor: If the machine is not moving as expected, the drive motor should be inspected for proper function. If necessary, the motor should be replaced or repaired.
  
• Clear blockages: Inspect all hydraulic lines for any signs of blockages or restrictions. Clean or replace any blocked lines to restore full hydraulic flow.
  
• Inspect bearings and components: If you hear unusual noises or notice slow movements, inspect the bearings for wear. Replacing worn bearings will restore the system’s smooth operation.
  
• Recalibrate the system: Follow the manufacturer’s guidelines for recalibrating the lift and drive system to ensure proper functionality.
  

4. Steering Problems
Steering issues in the JLG 40 RTS can make it difficult or impossible to control the machine, leading to reduced productivity and safety risks.
Potential Causes:

• Low steering fluid: Just like the hydraulic system, the steering system relies on fluid to operate. Low levels can cause the steering to become stiff or unresponsive.
  
• Worn steering components: Worn-out components, such as the steering pump or valve, can cause erratic or delayed steering responses.
  
• Damaged steering lines or connections: Leaks in the steering system can cause fluid loss and reduce steering effectiveness.
  

Solutions:

• Check steering fluid levels: Ensure that the steering fluid is at the proper level and top it up if necessary.
  
• Inspect steering components: Check the steering pump, valve, and other components for wear or damage. Replace any faulty parts to restore proper function.
  
• Fix leaks: Inspect steering hoses and connections for leaks and repair or replace as needed.
  

Preventive Maintenance Tips
To minimize the likelihood of encountering these issues with your JLG 40 RTS, it’s essential to maintain the machine regularly. Some key preventive maintenance practices include:

• Regularly check fluid levels: Keep an eye on both hydraulic and steering fluid levels, topping up as necessary.
  
• Inspect the electrical system: Regularly check batteries, fuses, wiring, and the solenoid for any signs of damage or wear.
  
• Clean and replace filters: Ensure that air, fuel, and hydraulic filters are clean and replaced according to the manufacturer's schedule.
  
• Lubricate moving parts: Proper lubrication of moving parts, including bearings and joints, will reduce friction and prevent premature wear.
  
• Conduct routine visual inspections: Regularly inspect the machine for visible signs of wear, leaks, or damage, and address any issues promptly.
  

Conclusion
Troubleshooting the JLG 40 RTS can be a complex process, but by understanding common issues and their causes, operators can address problems quickly and efficiently. Whether it’s electrical, hydraulic, or mechanical issues, timely diagnosis and repair can restore the machine’s full functionality. Regular preventive maintenance is key to avoiding many of these problems and ensuring the longevity of the equipment. By following the guidelines provided in this article, operators can keep their JLG 40 RTS performing optimally, reducing downtime and improving overall productivity.