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35827_A
COMPONENT TEST PROCEDURES
To be able to use these component test procedures safely and effectively, it is important to
read this guide completely before beginning any tests.
CAUTION: REPAIRS BY QUALIFIED PERSONNEL ONLY. NOTE – MODIFYING THIS
CHARGER FOR USE OTHER THAN THAT FOR WHICH IT WAS INTENDED, REPAIRS BY
PERSONS NOT QUALIFIED, OR NOT USING ORIGINAL EQUIPMENT REPLACEMENT
PARTS WILL VOID THE WARRENTY AND LESTER LIABILITY.
DANGER: HIGH VOLTAGE! WITH THE CHARGER ON, THE INTERNAL CHARGER
CAPACITOR VOLTAGE IS APPROXIMATELY 660 VOLTS.
CAUTION: ALWAYS UNPLUG THE AC AND DC CORDS FROM THE AC OUTLET AND
THE BATTERIES BEFORE ATTEMPTING ANY REPAIRS TO THE CHARGER.
WARNING: DO NOT OPERATE THE CHARGER IF IT IS MALFUNCTIONING.
PERSONAL INJURY OR PROPERTY DAMAGE COULD RESULT.
This battery charger is a reliable, automatic charger designed for long, trouble-free service. If
a component requires testing, identify the symptom and follow the associated test procedures.
SECTION
COMPONENT TESTING PROCEDURES
7
ELECTRONIC CHARGE CONTROLLER TESTING
7A
Relay Not Closing.
7B
Not Turing Off.
8 TRANSFORMER
TESTING
9
DIODE ASSEMBLY TESTING
10
CAPACITOR TESTING
11
AC INPUT CIRCUIT TESTING
12
DC OUTPUT CIRCUIT TESTING
7.
ELECTRONIC CHARGE CONTROLLER TESTING
The electronic charge controller is used to start and stop each charge cycle. It is designed to
sense both the AC input and DC battery pack voltages. When each of these is present, the
controller will connect the AC input to the transformer primary by closing the relay contacts.
When the controller senses that the battery pack is fully charged, it will open the relay contacts
thus terminating the charge cycle.
If the electronic charge controller is suspect of being bad after going through the
Troubleshooting Guide in the previous section, there are several tests in SECTION 7A and 7B
which can be performed to verify its operation. Remove the cover on the charger to conduct
each of these tests.
DANGER: HAZARD OF ELECTRICAL SHOCK. ONLY QUALIFIED PERSONNEL WHO
ARE KNOWLEDGABLE IN ELECTRICAL SAFETY PRECAUTIONS ARE TO TEST
EQUIPMENT WHILE ENERGIZED!
