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35827_A
3.
AMMETER READS 25 AMPS FOR MORE THAN 30 MINUTES
This high output condition is caused by misuse, connecting the charger to an incorrect battery
system that is lower than what is rated for the charger. A common error is to install one or
more of the batteries in a battery pack reverse polarity. Using a suitable DC voltmeter, test to
be sure all batteries in the battery pack are correctly wired, and also test the battery pack
voltage at the battery receptacle. After charging for 30 minutes at this excessive rate, the
measured on-charge voltage should rise to 34 volts DC or higher for a 36-volt system. While
charging, voltage measurements lower than this indicates an incorrect or failed battery pack
that must be corrected before using the charger.
CAUTION: DO NOT CONNECT THE CHARGER TO BATTERY PACKS WHICH ARE
NOT RATED FOR THE CHARGER. THIS MISUSE WILL CAUSE OVERHEATING AND
TRANSFORMER BURN-OUT WILL RESULT.
4.
CHARGER OUTPUT IS LOW
The most probable cause of low output is a single fuse link blowing as a result of a short circuit
failure of one diode. Refer to Item 2, "Charger Fuse Blows", for troubleshooting procedures.
Other possible problems which might cause the output to be low are the following:
•
Short circuit failure of a transformer coil
•
Loose wiring connection in the charging circuit
•
Capacitor
problem
•
Open
diode
Refer to Component Test Procedure section to check each of these potential issues.
CAUTION: DO NOT USE THE CHARGER IF THE OUTPUT IS LOW. BATTERIES WILL
NOT REACH FULL CHARGE, THEREBY INCREASING THE POSSIBILITY OF BATTERY
DAMAGE CAUSED BY DEEP DISCHARGE DURING THEIR NEXT USE.
5.
CHARGER TURN-OFF MALFUNCTIONS
The electronic charge controller turns the charger off as well as on. Proper charge time is
determined by many factors, but the main elements are: (1) battery size, (2) depth of battery
discharge, and (3) finish charge rate. Large, severely discharged batteries require more time
to reach full charge than do smaller, lightly discharged batteries.
The charge rate, as indiated by current flow in amperes on the ammeter, is controlled by the
batteries' rising voltage during charge. The higher the on-charge voltage will rise, the lower the
finish charge will be before the electronic charge controller terminates charging.
THE FOLLOWING CONTROLLER MALFUNCTIONS ARE OCCASIONALLY DUE TO
FACTORS OTHER THAN THE CHARGER'S PERFORMANCE, REFER TO SECTION 5A,
5B OR 5C. TO HELP ISOLATE THE PROBLEM, IT IS OFTEN NECESSARY TO USE THE
CHARGER ON A DIFFERENT SET OF BATTERIES AND THE ORIGINAL SET OF
BATTERIES ON ANOTHER CHARGER.
