Troubleshooting Guide
4
31039B
individually check the continuity of the DC output
cord, ammeter, diodes, and all connections. If
the circuit conducts in both directions, a "short"
exists in the charger DC circuit. First check the
DC output cord for a "short" between the two
wires. It is more likely that one or both diodes
have "shorted". Refer to Section 2, "Charger
Fuse Blows", for continuity test of diodes.
2.
If the charger DC circuit test is good, a check of
the capacitor is necessary. Disconnect the
power supply cord from its outlet and the DC
output connector from the battery connector.
Then disconnect both transformer coil leads
from the capacitor terminals. Use care when
disconnecting the capacitor leads so the wires
do not break. Using an ohmmeter, set the scale
to R x 10K ohms and test the capacitor as
follows:
GOOD CAPACITOR
When the ohmmeter leads are
connected to the capacitor
terminals, the meter needle jumps
to mid-scale and rapidly moves to
higher resistance (
:
)
OPEN CAPACITOR
When the ohmmeter leads are
connected to the capacitor
terminals, the meter needle does
not move and stays at high
resistance (
:
). A bulge in the top of
the capacitor may be visible if the
capacitor has failed "Open".
SHORTED CAPACITOR
When the ohmmeter leads are
connected to the capacitor
terminals, the meter needle jumps
immediately to zero ohms and
remains there.
If the capacitor is "Open" or "Shorted", it must be
replaced.
CAUTION: USE ONLY THE PROPERLY
RATED CAPACITOR FOR REPLACEMENT. THE
USE OF A DIFFERENT VALUE CAPACITOR MAY
RESULT IN IMPROPER CHARGING, CAPACITOR
FAILURE, TRANSFORMER BURN-OUT, AND/OR
BATTERY DAMAGE.
3.
If the charger DC circuit and capacitor check
good, a test of the transformer is necessary.
Refer to Section 7, "Transformer Short or Burn-
out" for test procedures.
Part D Electronic Timer Kit replacement
The Electronic Timer Kit should always be replaced
as a complete assembly. The tools required are a
Phillips head screwdriver, 3/8" and 11/32" wrenches,
and pliers. No soldering is required. To replace the
kit, follow the step-by-step procedures listed below.
1.
Disconnect the charger power supply cord from
its outlet and the DC output connector from the
battery connector, and remove the charger
cover.
2.
Disconnect the GREEN (if included), BLACK
and RED wires of the Electronic Timer Kit. Then
remove the BLACK and WHITE leads of the
power supply cord and both primary transformer
coil leads from the Electronic Timer Kit terminal
tabs. The Kit can be removed by removing the
three mounting screws on the charger front
panel. Save all hardware for reassembly.
3.
Install the replacement Electronic Timer Kit by
reversing the disassembly procedures described
in Step 2. When reconnecting the wires to the
Electronic Timer Kit terminal tabs, support the
terminal board to prevent damage to the
electronic circuit board. Connect either
transformer primary lead to terminal #2, and the
remaining primary lead to terminal #3.
Connect the BLACK lead of the power supply
cord to terminal #1 on the Electronic Timer Kit
and the WHITE lead of the power supply cord to
terminal #2.
Connect the RED wire of the Electronic Timer
Kit along with the WHITE or RED lead of the DC
cord to the Heatsink Assembly. Connect the
BLACK wire of the Electronic Timer Kit along
with the BLACK lead of the DC cord to the
ammeter post. Do not allow the ammeter post
to turn when tightening the nut. Reconnect the
GREEN wire of the Electronic Timer Kit along
with the transformer secondary lead to the diode
lead terminal (if included).
CAUTION: BE SURE ALL CONNECTIONS
ARE CLEAN AND TIGHT. ALSO CHECK TO BE
SURE ALL WIRES AND TERMINALS ARE
POSITIONED SO THEY DO NOT SHORT
TOGETHER OR TO THE CHARGER CASE.
4.
Replace the charger cover and check the
Electronic Timer Kit for proper operation as
follows:
a.
With the DC output connector disconnected
from the battery connector, insert the power
supply cord into an outlet. The relay on the
Electronic Timer Kit should not close. A DC
voltmeter connected across the DC output
connector should indicate zero volts.
b.
Disconnect the power supply cord from its
outlet and connect the DC output connector
to the battery connector. The relay on the
Electronic Timer Kit should close with an
audible "click" after a two to five (2-5)
second delay.
c.
If the Electronic Timer Kit does not operate
as (a) and (b) above, refer to the wiring
diagram and check to be sure the charger is
