www.lesterelectrical.com 1
35827_A
TROUBLESHOOTING, REPAIR, AND REPLACEMENT
GUIDE FOR MODEL #19300 BATTERY CHARGER
PLEASE SAVE THESE IMPORTANT SAFETY INSTRUCTIONS
For correct operation of the equipment, it is important to read and be familiar
with this entire manual before installing and operating the charger.
DO NOT DISCARD THIS MANUAL AFTER READING.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:
BECOME ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW
THESE SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN
OCCUR.
TABLE OF CONTENTS
INTRODUCTION ....................................................................................................................... 2
PROPER CARE OF MOTIVE POWER BATTERIES................................................................. 2
TROUBLESHOOTING GUIDE .................................................................................................. 3
1. CHARGER
DOES
NOT TURN ON............................................................................ 4
2. CHARGER
FUSE BLOWS ........................................................................................ 5
3.
AMMETER READS 25 AMPS FOR MORE THAN 30 MINUTES .............................. 6
4. CHARGER
OUTPUT IS LOW ................................................................................... 6
5. CHARGER
TURN-OFF MALFUNCTIONS ................................................................ 6
6.
AC LINE FUSE OR CIRCUIT BREAKER BLOWS .................................................... 8
COMPONENT TEST PROCEDURES ....................................................................................... 9
7. ELECTRONIC
CHARGE
CONTROLLER TESTING ................................................. 9
8. TRANSFORMER TESTING .................................................................................... 12
9. DIODE
ASSEMBLY TESTING ................................................................................ 14
10.
CAPACITOR TESTING ........................................................................................... 17
11.
AC INPUT CIRCUIT TESTING................................................................................ 19
12. DC OUTPUT CIRCUIT TESTING............................................................................ 20
COMPONENT REPLACEMENT PROCEDURES ................................................................... 21
13. ELECTRONIC CHARGE CONTROLLER REPLACEMENT .................................... 21
14.
DIODE ASSEMBLY REPLACEMENT ..................................................................... 23
15.
CAPACITOR REPLACEMENT................................................................................ 25
16. AC INPUT AND DC OUTPUT CORD REPLACEMENT .......................................... 26
17.
FUSE ASSEMBLY REPLACEMENT....................................................................... 27
CHARGER WIRING DIAGRAM............................................................................................... 28
CHARGER COMPONENTS EXPLODED VIEW ..................................................................... 29
SERVICE PARTS LIST ........................................................................................................... 29
*35827*
