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35827_A
7A. Relay
Not
Closing
Connect the AC input cord to a live outlet and DC output plug to the battery receptacle. Using
an appropriate multi-meter, set it to measure AC volts on a scale large enough to measure 120
VAC. Place the two meter probes across point A (screw head) and B (dual QD terminal) as
shown in Figure. 7A. If normal AC voltage is present, the AC input circuit is connected
properly.
Figure 7A
Figure 7B
Figure 7C
Adjust the multi-meter to measure DC voltage and place the test probes at the wire harness
connector on the electronic charge controller as shown in Figure 7B. The voltage measured
should be the same as the battery voltage pack. If the correct DC voltage is present, the DC
output circuit is connected properly. If not, check the connections at the battery receptacle, the
plug sense contact and sense wire, the controller wire harness, the diode assembly, and at the
ammeter.
If both the AC and DC voltages are present on the electronic controller and the charger still will
not start then check to make sure the screws holding the relay board assembly to the potted
electronic board are tight. A loose connection on these screws will prevent the charger from
starting. With the multi-meter adjusted to measure 120 volts AC, place the test probes across
points A (top screw head) and C (bottom screw head) as shown in Figure 7C. If input line
voltage is not present after the five-second delay time, the electronics have malfunctioned and
the electronic charger controller will have to be replaced. If input line voltage is present, then
the relay board assembly has failed and will have to be replaced.
Bypassing the electronic charge controller
The electronic charge controller may be bypassed in order to verify that a malfunction exists
with the controller. Disconnect the charger’s AC input cord from its outlet and the DC output
plug from the battery receptacle. Find the white wire from the transformer which attaches to
the NO terminal and the black AC input cord wire which attaches to the COM terminal on the
relay. Remove these two wires from the relay and connect them directly to each other as
shown in Figure 7D and 7E. We suggest that you fabricate a 14-gauge wire, three inches
long, that has 1/4 inch quick disconnect male terminals crimped and soldered onto both ends.
