Common Issues with JLG Aerial Work Platforms and How to Address Them

[MikePhua]

JLG Industries, established in 1969, has been a leading manufacturer of aerial work platforms, including boom lifts and scissor lifts. Their equipment is widely used in construction, maintenance, and industrial applications. However, like any complex machinery, JLG lifts can experience operational issues. Understanding these common problems and their solutions can help ensure safety and efficiency on the job site.
Hydraulic System Failures
Hydraulic systems are crucial for the movement and stability of aerial work platforms. Common hydraulic issues include:

• Oil Leaks: Leaks can occur due to damaged hoses, fittings, or seals. Regular inspection and maintenance are essential to identify and repair leaks promptly.
  
• Low Hydraulic Fluid: Insufficient fluid levels can lead to erratic movements or complete system failure. Always check and maintain the recommended fluid levels.
  
• Clogged Filters: Over time, filters can become clogged with debris, restricting fluid flow and causing system inefficiencies. Regularly replacing filters can prevent this issue.
  
• Hydraulic Pump Failures: A failing pump can result in loss of power and functionality. Symptoms include slow or unresponsive movements. If the pump is suspected to be faulty, it should be inspected and replaced by a qualified technician.
  

Electrical System Malfunctions
Electrical issues can affect various components of the lift, including controls, sensors, and power supply. Common electrical problems include:

• Battery Failures: A weak or dead battery can prevent the lift from starting or operating correctly. Regularly check battery health and replace it as needed.
  
• Faulty Wiring: Damaged or corroded wires can lead to intermittent or complete loss of power. Inspect wiring for signs of wear or damage and repair or replace as necessary.
  
• Sensor Issues: Sensors that monitor tilt, load, or position can malfunction, leading to safety concerns or operational errors. Regular calibration and testing of sensors can help maintain accuracy.
  

Control System Problems
The control system, including joysticks and control panels, is the interface between the operator and the lift. Issues here can lead to:

• Unresponsive Controls: This can be due to faulty joysticks, control boards, or communication errors within the system. Diagnosing the exact cause may require specialized diagnostic tools.
  
• Intermittent Operation: Sometimes, controls may work sporadically. This could be due to loose connections, damaged cables, or software glitches. Thorough inspection and testing can help identify the root cause.
  

Mechanical Failures
Mechanical components such as motors, gears, and structural elements can experience wear and tear over time:

• Motor Failures: Motors that drive the lift's movement can fail due to overuse, lack of maintenance, or electrical issues. Symptoms include unusual noises or lack of movement.
  
• Structural Wear: Regularly inspect the lift's structure for signs of stress, cracks, or corrosion. Addressing these issues promptly can prevent more serious problems.
  

Overheating Issues
Overheating can occur in both hydraulic and engine systems:

• Hydraulic Overheating: Caused by low fluid levels, contaminated fluid, or overuse. Symptoms include slow or jerky movements. Ensure proper fluid maintenance and avoid prolonged operation under heavy loads.
  
• Engine Overheating: Can be due to coolant issues, blocked air vents, or engine malfunctions. Regularly check coolant levels and ensure air vents are clear.
  

Safety System Alerts
Modern JLG lifts are equipped with safety systems that can trigger alerts or shutdowns:

• Tilt Sensor Alerts: If the lift detects an unsafe tilt angle, it may disable certain functions to prevent accidents. Ensure the lift is on stable ground and the sensor is calibrated correctly.
  
• Load Sensors: Overloading the lift can trigger safety shutdowns. Always adhere to the manufacturer's load capacity recommendations.
  

Maintenance and Troubleshooting Tips
To minimize downtime and extend the life of your JLG lift:

• Regular Inspections: Conduct daily pre-operation checks, including inspecting hydraulic fluid levels, battery charge, and structural integrity.
  
• Scheduled Maintenance: Follow the manufacturer's recommended maintenance schedule for tasks such as filter changes, lubrication, and component inspections.
  
• Use Diagnostic Tools: Utilize JLG's diagnostic tools and fault code readers to identify and address issues promptly.
  
• Training: Ensure operators are properly trained in using the lift and recognizing potential issues.
  

Conclusion
JLG aerial work platforms are reliable and efficient tools when properly maintained. By understanding common issues and implementing proactive maintenance practices, operators can ensure safe and effective use of these machines. Always consult the operator's manual and seek professional assistance when needed to address complex problems.