Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation, T Roubleshooting And Replacement Parts Manual Download Page 156

Page: 156 / 242

Battery Charger

Page 18

MN-402-000

While connected to an AC outlet, the charger cabinet must remain electrically grounded. Disconnect both of

the battery leads and unplug the charger from the AC source before disconnecting any electrical component or

wire. Failure to do so may result in serious bodily injury.

Troubleshooting, Portable Charger

1. Disconnect the charger from the AC outlet and the batteries

and perform the following tests:

• Test the voltage from the positive terminal on the vehicles

DC receptacle to main battery negative. This voltage should
be equal to the battery voltage. If the voltage is less than the
battery voltage then this wire is broken or has a bad
connection. Stop here and repair the problem.

• Test the voltage from the positive terminal on the DC

receptacle to the negative terminal on the DC receptacle. This
voltage should be equal to the battery voltage. If the voltage
is less than the battery voltage, then the wire on the negative
terminal of the DC receptacle is broken or has a bad
connection. Stop here and repair the problem.

2. Remove the charger cover and perform the following tests:

• Inspect the internal wiring of the charger and repair as

required.

• Check the continuity of both fuse links and replace if bad.
• Disconnect one lead from the capacitor. Test the capacitor

using the capacitor test function on the meter. If the capacitor
is bad, it must be replaced. Stop here and repair the problem.

• Reconnect the lead to the capacitor and disconnect one

transformer lead from one of the diodes. Test each of the diodes
using the diode test function on the meter. If either one of the
diodes are bad, replace the diode assembly. Stop here and
repair the problem.

3. Reconnect the lead to the diode.

4. Connect the charger to the AC source. Insert the DC

charger plug into the DC receptacle and perform the
following tests:

• Test the voltage from the fuse

assembly (-) to the diode block
(+). This voltage should be equal
to the battery voltage. If the
voltage is less than the battery
voltage, then the DC cord is bad.
Stop here and repair the problem.

• Test the voltage across the white

and black wires that are connected
to the timer board. This voltage
should be the same as the rated AC voltage of the charger. If
the voltage is less than the rated AC voltage of the charger
then the AC cord is bad. Stop here and repair the problem.

Note:

If the above tests are good and the timer relay
does not pickup (click) within 5 seconds of
connecting the DC charger plug, then the timer
control circuit or the relay is bad (refer to Timer
Relay Test). Stop here and repair the problem.

• Test the AC voltage across the

transformer primary circuit.
This voltage should be the same
as the rated AC voltage of the
charger. If it is less than the
rated AC voltage of the charger,
then the timer relay is bad. Stop
here and repair the problem.

• Test the AC voltage across the transformer secondary circuit.

The voltage here will vary depending on the state of charge
in the batteries. The voltage should be between 208% and
250% of the rated DC voltage of the charger. If the voltage is
not between 208% and 250% of the charge’s rated DC voltage,
the transformer is bad and must be replaced. Stop here and
repair the problem.

High Voltage inside the charger. Do not touch any

internal components while the charger is plugged

in. Failure to do so may result in serious bodily injury.