Troubleshooting JLG 40RTS Issues

[MikePhua]

The JLG 40RTS is a versatile rough-terrain scissor lift designed for construction, maintenance, and various other industrial applications. Known for its excellent mobility and lifting capabilities, the 40RTS is a popular choice in demanding environments like construction sites, where stability and ease of use are essential. However, like any piece of heavy machinery, issues can arise during operation, and understanding the common problems and their solutions is key to keeping the equipment running smoothly.
In this article, we will explore the typical problems operators face with the JLG 40RTS, how to troubleshoot them, and the steps required for repairs and preventive maintenance to ensure optimal performance.
Understanding the JLG 40RTS
The JLG 40RTS is part of the JLG family of aerial work platforms, which are used for lifting personnel and equipment to elevated positions. The 40RTS is known for its ruggedness and ability to handle challenging terrains, making it ideal for outdoor construction and maintenance tasks.
Key features of the JLG 40RTS include:

1. Rough Terrain Tires: These tires are designed to provide traction on uneven surfaces, making the 40RTS suitable for construction sites and other locations with difficult ground conditions.
   
2. Hydraulic Drive System: The machine uses a hydraulic system for its lift and drive functions, which is essential for powering its boom and platform.
   
3. Lift Capacity: The JLG 40RTS has a lifting capacity of around 500 lbs, providing ample space for workers and materials.
   
4. Operating Height: With a maximum working height of around 40 feet, the 40RTS allows workers to reach elevated areas for tasks such as maintenance, inspections, or installation work.
   

Despite its reliability, there are several common issues that can impact the performance of the JLG 40RTS.
Common Problems with the JLG 40RTS

1. Hydraulic System Failures
   The hydraulic system is the heart of the JLG 40RTS, responsible for the movement of the platform, boom, and other key functions. However, like all hydraulic systems, it can experience issues that hinder the performance of the machine.
   • Symptom: The lift may struggle to raise or lower, or the platform may move erratically.
     
   • Possible Causes: Low hydraulic fluid levels, air in the hydraulic lines, or a malfunctioning hydraulic pump. In some cases, hydraulic leaks in hoses, fittings, or cylinders can also lead to reduced pressure and performance.
     
   Solution:
   • Check the hydraulic fluid levels and top them off if necessary.
     
   • Inspect the hydraulic hoses and fittings for any signs of leaks or damage.
     
   • Bleed the system to remove any air trapped in the lines.
     
   • If the hydraulic pump is malfunctioning, it may need to be replaced or repaired by a professional.
     
2. Electrical and Control System Problems
   The electrical and control systems of the JLG 40RTS are crucial for powering the lift’s movements and safety features. When these systems malfunction, it can cause significant operational issues.
   • Symptom: The lift may fail to respond to control inputs, or the control panel may display warning lights or error codes.
     
   • Possible Causes: Faulty wiring, blown fuses, or a malfunctioning control module. Poor connections or corroded terminals can also lead to intermittent or complete failures in the control system.
     
   Solution:
   • Inspect the wiring for loose connections or signs of wear and tear.
     
   • Check and replace any blown fuses in the system.
     
   • Use a diagnostic tool to read any fault codes from the control module. Repair or replace any damaged control components.
     
3. Battery or Power Supply Issues
   The JLG 40RTS relies on its battery to power its electrical systems when not connected to an external power source. If the battery is weak or damaged, it can lead to power issues that prevent the machine from operating.
   • Symptom: The platform or boom may not raise, or the lift may not start.
     
   • Possible Causes: A dead or weak battery, poor battery connections, or a faulty alternator that fails to charge the battery while the lift is in use.
     
   Solution:
   • Check the battery’s charge level and replace it if necessary.
     
   • Inspect the battery terminals for corrosion and clean them if needed.
     
   • Test the alternator to ensure it is charging the battery correctly. If the alternator is faulty, it may need to be repaired or replaced.
     
4. Mechanical and Drive System Problems
   The mechanical components of the JLG 40RTS, such as the lift arms, tracks, and drive motors, are subject to wear and tear over time, especially in rough terrain.
   • Symptom: The machine may move slowly or struggle to climb inclines, or the lift may not fully extend.
     
   • Possible Causes: Worn-out drive motors, low hydraulic pressure, or damaged mechanical parts such as pins, bushings, or tracks.
     
   Solution:
   • Inspect the drive motors and hydraulic system for signs of wear or damage.
     
   • Check the tracks for proper tension and alignment. If the tracks are worn or damaged, they may need to be replaced.
     
   • Lubricate all moving parts according to the manufacturer’s maintenance schedule to prevent wear.
     
5. Faulty Safety Systems
   The JLG 40RTS is equipped with safety systems designed to prevent accidents and ensure safe operation. These systems may include tilt sensors, platform load sensors, and emergency stop buttons.
   • Symptom: Warning lights or alarms may sound, or the lift may not operate even if the controls are functioning.
     
   • Possible Causes: A faulty safety switch or sensor, or a malfunction in the system that monitors load or tilt.
     
   Solution:
   • Check all safety switches and sensors for proper operation. Replace any faulty components.
     
   • Inspect the tilt sensor and load sensor for accuracy and functionality.
     

Preventive Maintenance for the JLG 40RTS
To keep the JLG 40RTS in optimal condition and avoid common issues, regular maintenance is essential. Some key maintenance practices include:

1. Regular Hydraulic Checks: Inspect the hydraulic fluid levels regularly and top them off as needed. Check for leaks in the hydraulic lines and fittings and replace damaged parts promptly.
   
2. Battery Maintenance: Ensure that the battery is charged and clean, with no corrosion on the terminals. Regularly check the battery voltage and replace the battery if it no longer holds a charge.
   
3. Wiring and Electrical Inspections: Inspect the wiring and control systems for loose connections or damaged components. Periodically test the control panel and replace any faulty fuses or relays.
   
4. Lubrication: Keep all moving parts properly lubricated, especially the boom and platform joints. This reduces friction and wear, ensuring smooth operation.
   
5. Track and Drive System Checks: Regularly inspect the tracks, drive motors, and other mechanical components for wear. Replace any worn-out parts and adjust the tracks for proper tension.
   

Conclusion
The JLG 40RTS is a reliable and versatile lift that can tackle challenging jobs on rough terrain, but like all heavy machinery, it requires proper maintenance and troubleshooting when issues arise. By understanding the common problems associated with this machine and taking preventive measures, operators can ensure that their JLG 40RTS continues to perform efficiently, minimizing downtime and maximizing productivity. Regular checks, timely repairs, and adhering to maintenance schedules will help keep this powerful equipment running smoothly for years to come.