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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 and Warnings.
B
Looping the DC cord through the steering wheel when charg-
ing serves as a good reminder to store the cord out of the way
when finished with charging. The DC plug can be damaged by
driving over or catching the cord on the vehicle when driving
away.
An ungrounded electrical device may become
a physical hazard that could result in an electri-
cal shock or electrocution.
UNDERSTANDING THE CHARGER
When the charger is plugged into the vehicle’s charger
receptacle, the charger will automatically turn on and the
charger’s LED will start flashing GREEN to indicate the
batteries are charging.
Once a minimum battery voltage of 2 volts per cell (Vpc)
is reached, the charger’s output current will change from
a full current charge to the trickle rated charging current.
The length of charge time will vary by how depleted the
batteries are, the input AC voltage, and/or charger ambi-
ent temperatures. The charger’s LED will give a SHORT
flash if the charge is less than 80% and a LONG flash if
the charge is greater than 80%. If the charger’s LED is a
steady GREEN the batteries are fully charged and the
charger may be unplugged, although not necessary. The
charger may be left plugged in for long periods of time to
maintain the batteries charge level.
If a fault occurred anytime during the charging, the
charger’s LED will quickly flash RED. The specific fault
is indicated by the number of RED flashes that occur,
there will be a pause and then the flashes will repeat
again. There are several possible conditions that will
generate errors. Some errors will require human inter-
vention to first resolve the problem and then reset the
charger by unplugging the DC cord from the vehicle.
If the AC voltage is interrupted and restored, the charger
will turn back on automatically.
LED DISPLAY INFORMATION
LED Operation Codes:
SHORT GREEN FLASH = less than 80% charged
LONG GREEN FLASH = more than 80% charged
SOLID GREEN = 100% charged
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 - Charge Enable
Fault: poor contact in the DC connector or dirty
contacts or Battery Temperature Fault: battery
temperature is 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. This indicates a
problem with the battery pack voltage not reach-
ing the required nominal level within the maxi-
mum time allowed.
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 DC power cord and plugging it back in,
the charger must be taken to a qualified service
center.
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 battery charger and the vehicle
receptacle housing for dirt or debris. Clean the DC
connector monthly or more often if needed.
NOTICE
