4.5.1 CHARGER OPERATING INSTRUCTIONS
Connect the supplied power cord to the vehicle charger receptacle and to a properly grounded wall outlet.
Charger start and charge time is automatic. The yellow AC power LED (Fig. 4.5A No. 1) should remain
illuminated while the charger is plugged into an AC source. The remote LED will be flashing short green. If
these LED’s are not lit, before replacing charger, recheck the AC connection and the AC source fuse or
breaker. If this fails to correct the problem, contact your Tomberlin dealer for assistance.
Charger will automatically turn on and conduct a short self-test and battery pack test. All charger LED’s
will flash in sequence and then a trickle current will be applied to batteries until a minimum voltage is
reached. In Figure 4.5A No. 3 indicates the bar graph and No. 2 indicates the lowest LED. Three (3) amperes
is displayed as the lowest LED on the bar graph.
If the batteries meet the minimum voltage requirements of the charger program, signifying they are
serviceable (chargeable), the charger enters the bulk charging stage (higher amperage-constant current).
The bar graph LED’s indicate the electrical current being delivered to the batteries as the charger moves
through its automatic charge program. The length of charge time at each level will vary based on battery
size and battery charge depletion. The remote LED will be flashing short green.
NOTICE: If the batteries are excessively discharged, the on-board charger will not be able to charge the complete
set of batteries. The charger red fault LED (Fig. 4.5A No. 6) will flash and the remote LED will also be flashing red.
(See Section 4.5.2 Red Light Charger Error Codes). It will then be necessary to follow the Special Charging for
Excessively Discharged Batteries, Section 4.6.
When the yellow 80% LED (Fig 4.5A No. 4) is lit, the charger has completed the bulk stage and the batteries
are at approximately 80% state of charge. The 80% LED remains on as the last 20% of charge is returned
to the batteries in the second phase (constant voltage phase). At this time the remote LED will flash long
green.
NOTICE: You can terminate charging at this point if necessary. The vehicle can be used, but completing the charge
cycle at the next available opportunity is highly recommended.
Charge completion is when the 100% green LED is lit (Fig. 4.5A No. 5). The remote LED will also be green.
Repeated “short charging” (leaving the charge short of 100%) will shorten operating distance and
significantly reduce overall battery life.
A low current “finish-charge” phase returns and maintains batteries to maximum capacity. The 100%
green LED’s will blink until “finish charge” phase is complete.
A 100% green LED continuously lit indicates the batteries are completely charged. The charger may now
be disconnected from the AC source.
If the vehicle will not be used for a length of time, check monthly for the charge level. It is also acceptable
to leave the on-board charger plugged in, as it has the capability to test and recharge if necessary.
A fault occurring while charging causes the red fault LED and the remote LED to flash with a code relaying
the error. Some errors may require repair by a qualified technician and others may be simply transient
and will automatically recover when the fault condition is eliminated and the charger cycled by
disconnecting the AC source for a minimum of 20 seconds.
NOTICE: A yellow (amber) flashing LED in the upper bar graph (Fig. 4.5A No. 3) and a flashing yellow remote LED
indicates the thermostatic control has limited the charger output due to ambient temperature conditions. It is
still charging, but at a reduced rate which will increase charging time.
