Technician Service Guide 33367B
2
To discourage end users from disassembling the
charger, Underwriters Laboratories and Canadian
Standards Association require that the internal
replaceable fuses be omitted from the Owners
Manual wiring diagram and parts list for specific
models. Those parts are included in the service
wiring diagram contained in this service guide.
PROPER CARE OF DEEP-CYCLE BATTERIES
Batteries used on industrial equipment are subjected
to severe deep-cycle duty on a daily basis. For this
reason, it is important that only deep-cycle batteries
are used. Although these batteries are designed to
withstand such duty, the following precautions must
be observed to obtain good performance and
maximum cycle life.
1. New batteries should be given a full charge
before their first use because it is difficult to
know how long the batteries have been stored.
2. Limit the use of new batteries for the first 5
cycles. New batteries are not capable of their
rated output until they have been discharged a
number of times.
3. Do not excessively discharge batteries.
Excessive discharge can cause polarity reversal
of individual cells resulting in complete failure
shortly thereafter. Limited use of new batteries
will minimize the chance of cell reversal.
4. CHECK THE LEVEL OF THE ELECTROLYTE
IN CONVENTIONAL LIQUID ELECTROLYTE
LEAD ACID BATTERIES MONTHLY.
MAINTAIN THE PROPER ELECTROLYTE
LEVEL BY ADDING WATER WHEN
NECESSARY. Electrolyte levels lower during
discharge and rise during charge. Therefore, it
is mandatory that water be added to cells ONLY
when they are fully charged; do not overfill. Old
batteries require more frequent additions of
water compared to new batteries.
5. Keep tops of batteries clean and dry to prevent
excessive self-discharge. Keep battery
terminals reasonably tight.
6. Sulfation results when batteries in storage are
not maintained in a charged, active state.
Internal self-discharge can bring about the start
of this condition in as little as three days in warm
temperatures. Batteries allowed to sit
unmaintained in storage will self-discharge,
sulfate to various degrees and lose capacity.
Repeated charging will generally result in the
recovery of most of the battery’s capacity,
though some permanent loss can be expected.
BATTERY TYPES
Battery manufacturers frequently use the same
battery cases for different battery types.
Replaceable liquid electrolyte deep-cycle batteries
have removable caps. Water electrolyzed by
discharging and charging the battery is replaced
through these openings.
Gel cell and sealed “maintenance–free” deep-cycle
batteries are generally distinguished by non-
removable cell caps. The physical appearance of
the battery case is frequently the same as that of a
replaceable liquid electrolyte battery though the cell
caps are generally not removable.
Refer to the battery manufacturer’s information
panel on the battery case to determine the type of
battery you have. If the information panel is missing
or not legible, do not use the battery. Refer to your
dealer if you do not understand what type of battery
you are using and have them set the “BATTERY
TYPE” switch on the charger accordingly, if
equipped.
The “BATTERY TYPE” switch is a two-position slide
switch visible on the front of the charger. Using a
small screwdriver, slide the switch from one setting
to the other through the opening. Take care not to
damage the switch when moving it to the desired
setting.
PERSONAL PRECAUTIONS
1. Someone should be within range of your voice
or close enough to come to your aid when you
work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in
case battery acid contacts skin, clothing or eyes.
3. Wear complete eye and clothing protection.
Avoid touching eyes while working near
batteries.
4. If battery acid contacts skin or clothing, wash
immediately with soap and water. If acid enters
eye, immediately flood eye with running cold
water for at least 10 minutes and get medical
attention immediately.
5. NEVER smoke or allow a spark or flame in the
vicinity of batteries.
6. Be extra cautious to reduce risk of dropping a
metal tool onto battery. It might spark or short
circuit battery or other electrical part that may
cause explosion.
