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BATTERY CHARGER
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
LED DISPLAY INFORMATION
LED Operation Codes:
SHORT GREEN FLASH = less than 80% charged
LONG GREEN FLASH = more than 80% charged
SOLID GREEN = 100% charged
LONG AMBER = charger is operating in reduced
output mode due to thermal cutback
RED FLASH = fault code
LED Fault Code:
RED FLASH: Light turns on briefly, but does not
flash after that - check for valid AC voltage.
ONE RED FLASH: One flash, a pause and then
again one flash and a pause - Battery Tempera-
ture Fault: battery temperature is out of range
(greater than 122° F (50° C) or less than 14° F (-
10° C)).
TWO RED FLASHES: Two flashes, a pause and
then again two flashes and a pause - Battery Volt-
age Fault: Battery pack is less than 36.0 Volts or
more than 67.2 Volts. Battery pack is too dis-
charged or over charged for the charger to work.
THREE RED FLASHES: Three flashes, a pause
and then again three flashes and a pause - Bat-
tery Charge Time-out: Charge time exceeded.
This may indicate a problem with the battery pack
or that the charger output current was severely
reduced due to high ambient temperatures.
FOUR RED FLASHES: Four flashes, a pause and
then again four flashes and a pause - Battery
Fault: Charge time exceeded (16 hours) with bat-
tery voltage still below nominal voltage. This indi-
cates a problem with the battery pack voltage not
reaching the required nominal level within the
maximum time allowed.
FIVE RED FLASHES: Five flashes, a pause and
then again five flashes and a pause - Internal
over temperature shut down.
SIX RED FLASHES: Six flashes, a pause and
then again six flashes and a pause - Charger
Fault: An internal fault has been detected. If this
fault is displayed again after unplugging the
charger’s power cord and plugging it back in, the
charger must be taken to a qualified service cen-
ter.
MAINTENANCE INSTRUCTIONS
1. For flooded lead-acid batteries, regularly check the
water levels of each battery cell after charging and
add distilled water as required to the level specified by
the battery manufacturer. Follow the safety instruc-
tions recommended by the battery manufacturer.
2. Make sure the charger connections to the battery ter-
minals are tight and clean. Check for any deforma-
tions or cracks in the plastic parts. Check the charger
harness for chaffing and rubbing. Inspect all wiring for
fraying, loose terminals, chaffing, corrosion or deterio-
ration of the insulation.
3. Keep the cooling fins free of dirt and debris, do not
expose the charger to oil, dirt, mud or to direct heavy
water spray when cleaning equipment.
4. Inspect the plug of the vehicle charger receptacle for
dirt or debris every time the power cord is connected.
REPLACING THE CHARGER/DC to DC
CONVERTER
Tool List
Qty.
Rubber Mat ..................................................................1
Torque Wrench, in. lbs. ................................................1
Ratchet ........................................................................1
Socket, 10 mm .............................................................1
Wrench, 10 mm............................................................1
Wrench, 7 mm..............................................................1
Removal
1. Turn the key switch to ’OFF’ and remove the key from
the switch.
2. Raise and remove the seat bottom.
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