Technician Service Guide 33367B
3
7. Remove personal metal items such as rings,
bracelets, necklaces and watches when working
with a lead-acid battery or charger. A lead-acid
battery can produce a short-circuit current high
enough to weld a ring or the like to metal,
causing a severe burn.
8. NEVER allow a battery to freeze and NEVER
attempt to charge a frozen battery.
CHARGER TEST PROCEDURES
Disconnect both the AC and DC charger cordsets.
Remove the screws on each side of the charger and
lift the cover off. Refer to the service wiring diagram
in this service guide and compare to the charger
under test to locate the described test points. Make
sure that all the charger’s internal connections are
secure and tight.
SECTION
MALFUNCTION SYMPTOM
PAGE
1
Charger Does Not Turn On
3
A
Indicator lights do not
illuminate after connections
to AC and battery are made.
3
B
Indicator lights illuminate but
charger does not produce
output.
5
C
Indicator lights illuminate,
charger produces output but
ammeter does not deflect.
6
2
Charger Does Not Turn Off
6
A
Does not turn off.
7
B
Turns off too soon or runs
too long.
7
3
Transformer Testing
8
A
Test Output Coil
8
B
Test Auxiliary Coil
8
4
SCR Testing
9
5
Charger AC Circuit
Breaker Trips/Fuse Blows
10
6
Charger DC Circuit
Breaker Trips/Fuse Blows
11
7
Building Circuit Breaker
Trips/Fuse Blows
11
8
Factory Assistance
12
SECTION 1 – CHARGER DOES NOT TURN ON
The electronic timer kit is powered by the battery
and/or the AC line voltage and will not operate
unless powered by the proper DC battery voltage
and polarity and/or AC line voltage. The minimum
amount of DC voltage required for the charger to
recognize a battery is connected varies by model.
Table 1 will provide general guidelines for testing but
may not represent the actual minimum voltage,
which may be lower.
Charger Nameplate
DC Voltage
Typical DC Voltage
Required
12
8
24
16
36
25
48
33
Table 1
Inspect and test for good AC and DC fuses/circuit
breakers before proceeding with this test. If either
the AC or DC fuse is blown or circuit breaker has
tripped, proceed to the appropriate section for the
AC or DC protection device involved.
PART A
Indicator light(s) do not illuminate after
connections to AC line voltage and battery
system are made.
Measure and record battery system DC voltage
at battery posts of machine.
Connect the positive (+) voltmeter lead to the
positive (+) battery system post and the Negative (-)
voltmeter lead to the negative (-) battery system
post. Reread the charger nameplate information for
the specified DC VOLTS and verify the battery
system has the proper DC voltage for the charger.
If battery maintenance has recently been performed,
check the battery system to determine if a battery
has been installed reverse polarity. A common error
is to install one or more 6-volt batteries in a battery
pack in reverse polarity.
Measure and record battery DC voltage at
charging receptacle.
If no DC voltage is measured or the DC voltage
measured is lower than the DC voltage measured at
the batteries, repair or replace charging wires,
attachments, and circuitry in equipment.
Measure and record battery DC voltage inside
charger case.
With both AC cord and charging plug disconnected,
remove the cover from the charger and refer to the
wiring diagram for that model of charger. Connect
the positive voltmeter lead to the same point inside
the charger where the WHITE (+) DC cord lead
connects. Connect the negative voltmeter lead to
