131 Eisenhower Lane North
Lombard, IL 60148
630.268.0010 / 1.800.251.2408
P/N 53-00660-100 Rev. A 081401
www.Intellitecsve.com
Intellitec
SERVICE MANUAL
BATTERY GUARD 2000
The control module gets its power from the inline fuse connected to the Battery Disconnect relay. It monitors the
voltage on the battery through this lead. When it senses that the voltage on the battery is less than 12.0 volts, it
momentarily a12 volts to Battery Disconnect relay to disconnect the power. It then blinks the LED indicator on
the dash mounted reset switch to indicate the disconnect.
The ignition input signal to the module is used to prevent the module from disconnecting the battery if the ignition is on.
This connection is
very
important. Failure to make this connection could result in the disconnecting of the battery
while driving.
WARNING
This could lead to serious driving difficulties and a fatal accident.
TESTING
The first step in testing
Battery Guard 2000
is to locate and press the
RESET
switch for a minimum of 3 seconds
continuously. This will quickly determine if the system is working properly.
RESET SWITCH TEST
To test the system, turn off the ignition and press the
RESET
switch for a minimum of 3 seconds continuously. The
battery should be disconnected and the dash mounted indicator should be blinking, momemtarily. Press the
RESET
switch to reconnect the battery.
Turn the ignition switch on, but
DO NOT
start the engine. LED should illuminate for 2 seconds. Again, press the
RESET switch and hold for 3 seconds continuously. The disconnect relay should not click, but will remain ON. The
dash indicator should not be blinking.
If these steps work, the system is working properly. If they don’t, check the inline 5 Amp fuse and repeat the first step.
If this fails to make the system work, further testing is required to determine the source of the failure.
SYSTEM TEST
The next step is to determine if the module is driving the Battery Disconnect relay coil. First, the Ignition should be in
the "OFF" position. Connect a test light across the “I” and “S” terminals of the relay. Press the
RESET
switch, hold for
3 seconds continously and observe the light. It should blink on. Press the
RESET
switch. The light should blink on
again. Failure to do this indicates the module, harness, or RESET switch is defective. The most probable cause of
failure is the module. If the test light blinks but the relay fails to click, the relay is defective.
BATTERY DISCONNECT RELAY TEST
Before attempting to test the Battery Disconnect relay,
UNPLUG
the wire harness from the control module.
CAUTION:
Failure to unplug harness before ap12 volts to these terminals WILL damage the controller.
To latch or turn the relay on, ground the “S” terminal and
momentarily
apply +12 volts to the “I” terminal. The relay
should click and engage, closing the circuit between the battery and the electrical system. To unlatch or turn off the
relay, ground the “I” terminal and
momentarily
apply +12 volts to the “S” terminal. The relay should click, opening the
circuit between the battery and the electrical system.
CAUTION:
Momentarily apply +12 Volts
ONLY,
in both cases.
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