BATTERY CHARGER
Page I-1
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
B
CHARGER DESCRIPTION
The on-board charger with built in DC to DC converter is
automatic and is designed specifically for charging elec-
tric vehicle batteries.
When the power cord is plugged into an external power
source the on-board charger will automatically turn on
and the vehicle’s power receptacle LED will start flash-
ing GREEN to indicate the battery is charging.
When the LED is GREEN continuously the batteries are
fully charged.
Risk of electric shock. Connect charger
power cord to an outlet that has been prop-
erly installed and grounded in accordance
with all local codes and ordinances. A
grounded outlet is required to reduce risk
of electric shock – do not use ground
adapters or modify plug. Do not touch unin-
sulated portion of output connector or
uninsulated battery terminal. Disconnect
the power cord before making or breaking
the connections to the battery while charg-
ing. Do not open or disassemble charger.
Do not operate charger if the AC supply
cord is damaged or if the charger has
received a sharp blow, been dropped, or
otherwise damaged in any way – refer all
repair work to qualified personnel. Not for
use by children.
Fig. 1 Charger Installation
The power cord may remain plugged into the AC outlet.
To charge the vehicle refer to the instructions in the
owner’s manual. Insert the polarized DC plug completely
into the vehicle receptacle. The charger will automati-
cally start a few seconds after the plug is in place. The
charger will automatically stop when the batteries are
fully charged and the power cord can be removed to
permit use of the vehicle.
Looping the power cord through the steering wheel when
charging serves as a good reminder to store the cord out of the
way when finished with charging. The 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 a power cord 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 up to 24 hours.
If a fault occurred anytime during the charging, the
receptacle’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
intervention to first resolve the problem and then reset
the charger by unplugging the power cord from the vehi-
cle.
If the AC voltage is interrupted and restored, the charger
will turn back on automatically.
DANGER
Provide Protection From Elements
Keep cooling fins clean and free of dirt and debris
NEMA 15 - 5R Grounded AC Receptacle
110 - 120 VAC. Dedicated 15 AMP Circuit
Locations outside the US and Canada: Reference
appropriate local electrical code and charger manu-
facturer recommendations for AC power requirements
NOTICE
