Troubleshooting Guide
3
31039B
WARNING: IF THE PLUG OR RECEPTACLE
IS BROKEN, TWISTED, BENT OR LOOSE AND
DOES NOT MAKE GOOD ELECTRICAL
CONTACT, HAVE IT REPLACED BY A
QUALIFIED SERVICE AGENT IMMEDIATELY. DO
NOT USE THE CHARGER IN THIS CONDITION
AS FIRE OR PERSONAL INJURY CAN RESULT.
Then disconnect the power supply cord from its
outlet. With the DC output connector still connected
to the battery connector, measure the voltage at the
battery connector using a suitable DC voltmeter.
The voltage reading should be the same as the
battery terminal voltage and must be 70% of the
nominal rating of the battery pack. Example: 24VDC
batteries need at least 16.8 VDC. If the DC voltage
is within the above limits, remove the charger cover
and verify that the charger is properly wired and you
read the same voltage (24 to 50 VDC) inside the
charger where the WHITE and BLACK wires of the
DC cord attach. If the battery DC voltage measured
inside the charger is now below the above limits or
not present, the DC plug or cordset has an internal
break and must be replaced. If the charger is wired
correctly and a satisfactory battery DC voltage is
measured inside the charger, a malfunction in the
Electronic Timer Kit has probably occurred. Due to
its complexity, do not attempt to make field repairs to
any part of the Electronic Timer Kit. If a malfunction
exists, simply remove the entire Electronic Timer Kit
and replace it with a new one. Refer to Part D,
"Electronic Timer Kit Replacement", for correct
procedure.
The Electronic Timer Kit may be bypassed in order
to verify that a malfunction exists. First disconnect
the charger power supply cord from its outlet and the
DC output connector form the battery connector.
Place a jumper wire between terminals #1 and #3 to
bypass the Electronic Timer Kit as shown in Figures
1 and 2.
The power supply cord is now connected directly to
the primary transformer coil and the transformer
should hum when the power supply cord is
connected to a live outlet. The charger operation
may be checked by first connecting the DC output
connector to the battery connector, and then
connecting the power supply cord to an outlet. If
normal charging current is indicated on the
ammeter, the Electronic Timer Kit is defective and
must be replaced.
CAUTION: DO NOT CHARGE BATTERIES
WITH THE ELECTRONIC TIMER KIT BYPASSED.
THE CHARGER WILL REMAIN ON AS LONG AS
THE POWER SUPPLY CORD IS CONNECTED TO
AN OUTLET. SEVERE OVERCHARGING AND
EVENTUAL DAMAGE TO BATTERIES WILL
RESULT.
If the transformer does not hum and the ammeter
still does not register with the Electronic Timer Kit
bypassed, a continuity check of the charger AC
circuit is necessary. Disconnect the power supply
cord from its outlet and the DC output connector
from the battery connector and, with a suitable
continuity tester, check the circuit across the power
supply cord prongs. With the Electronic Timer Kit
bypassed, the CIRCUIT SHOULD BE COMPLETE.
If the circuit is not complete, individually check the
continuity of the power supply cord, primary
transformer coil and all connections.
Part B Relay closes, but no transformer
hum, and ammeter does not register
Check to be sure the power supply cord is securely
connected to a live AC outlet. When three-prong to
two-prong adapters are used, they tend to work
loose, resulting in a poor connection. Check the AC
line fuse or circuit breaker and, if possible, measure
the AC line voltage at the outlet to be sure AC power
is present. If necessary, connect a functioning
charger, utility light, or other electrical appliance to
the outlet to verify the presence of AC power.
If AC power is present, disconnect the power supply
cord from its outlet and the DC output connector
from the battery connector. Bypass the Electronic
Timer Kit as described in Section 1, Part A, and with
a suitable continuity tester, check the circuit across
the power supply cord prongs. With the Electronic
Timer Kit bypassed, the CIRCUIT SHOULD BE
COMPLETE. If the circuit is complete, refer to the
Wiring Diagram and check the relay wiring and all
connections. If the circuit is not complete, check the
wiring of the power supply cord, transformer primary
coil leads, and the Electronic Timer Kit. If the
charger is wired correctly, individually check the
continuity of the power supply cord, transformer
primary and relay.
Part C Relay closes, and transformer hums,
but ammeter does not register
If the relay closes and the transformer hums, the
charger AC circuit and Electronic Timer Kit are
functioning properly. If the ammeter does not
register, a fault in the charger DC circuit exists and a
continuity check must be performed. Disconnect the
power supply cord from its outlet and the DC output
connector from the battery connector, and check the
charger fuse. If a fuse link is blown, refer to Section
2, "Charger Fuse Blows", for further tests. If the fuse
checks good, use a low voltage continuity tester to
perform the following tests:
1.
Connect the tester leads to the charger DC
output connector and note the readings.
Reverse the tester leads and check the output
connector again. The circuit should be complete
in only one direction. If the circuit does not
conduct in either direction and the fuse is good,
