SYMPTOM
POSSIBLE CAUSES
ACTION
Charger does not
react to battery be-
ing connected, and
display remains OFF .
1
Battery not connected properly .
Check battery connectors/harness .
2
Charger has been connected to
forklift motor connector .
Disconnect forkift motor and connect
battery .
3
Output fuse blown .
Replace output fuse and adjust AC input
settings .
4
Output cables reversed .
Check charger, connectors and battery
polarities . Output fuse is probably blown .
5
Bad control board connection .
Check board connectors (green) .
6
Bad control board .
Replace control board .
When battery is
connected,
message
appears .
1
AC input is absent .
Check AC input voltage on each phase .
Check AC input connections . Check AC
disconnect switch and fuses .
2
Bad contactor .
Replace contactor and freewheeling diode .
Output current is too
high
1
Wrong AC input settings .
Adjust AC input settings to higher voltage .
2
One or more cells are shorted .
Repair battery .
Output current is too
low
1
Wrong AC input settings .
Adjust AC input settings to lower voltage .
2
One AC phase is absent .
Check AC input voltage on each phase .
3
One or more diodes blown .
Replace rectifier .
4
Bad contactor .
Replace contactor .
Charger smells hot
1
Bad location .
Install the charger in proper location .
2
Ventilation slots obstructed .
Remove objects which may obstruct slots .
3
Wrong AC input settings .
Adjust AC input settings to higher voltage .
4
Bad or loose power wirings .
Check and thighten all power wirings .
5
Transformer burned .
Replace transformer .
Charger too noisy
1
Bad contactor .
Replace contactor and freewheeling diode .
2
One or more diodes shorted .
Replace rectifier .
Battery has low S .G .
and/or doesn't last
full shift
1
Wrong AC input settings .
Adjust AC input settings to lower voltage .
2
Battery capacity too low .
Replace battery .
Battery temperature
too high .
1
Wrong AC input settings .
Adjust AC input settings to higher voltage .
2
Battery power demand too
high .
Consider purchasing bigger Ah battery .
3
Insufficient cool down time .
Increase cool down time before/after
charging .
4
Automatic stop doesn't work .
Check and replace board and/or contactor .
TROUBLE SHOOTING
17