Taylor-Dunn MX-026-00, Руководство по эксплуатации, обслуживанию и замене запасных частей

Страница: 129 / 192

Battery Charger
Page 5
Troubleshooting, Built-in Charger
5. Disconnect the charger from the AC power source.
6. Locate the charger harness connectors where the charger
harness is connected to the vehicle’s control harness.
There will be two 10 gauge and two or four 14 gauge wires.
7. Slide the insulators off the connectors on the two 10 gauge
wires and perform the following tests:
•
Test the voltage from the vehicle harness red wire to main
battery negative terminal. This voltage should be equal to the
battery voltage. If the voltage is less than the battery voltage,
then this wire is broken or has a faulty connection. Stop here
and repair the problem.
•
Test the voltage from the vehicle harness red wire to the other 10
gauge wire (white or black depending on model). This voltage
should be equal to the battery voltage. If the voltage is less
than the battery voltage, then the white (or black) wire is broken
or has a faulty connection. Stop here and repair the problem.
8. Slide the insulators back onto the connectors on the two
10 gauge wires.
9. Slide the insulators off the connectors on the Black and
White 14 gauge wires.
10. Re-Connect the charger to the AC source and perform the
following tests:
•
Test the voltage across the Black and White 14 gauge wires. This
voltage should be the same as the voltage at the AC receptacle
(rated voltage of the charger). If the voltage is less than the rated
AC voltage of the charger then the 14 gauge white or black
wire(s) is broken or has a bad connection between the charger
connectors and the AC plug. Stop here and repair the problem.
11. Disconnect the charger from the AC power source.
12. Disconnect the batteries.
13. Remove the charger from the vehicle.
1. Make sure the start switch is in the “OFF”
position, then remove the key.
2. Place the forward-reverse switch in the center
“OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent
vehicle movement.
While connected to an AC outlet, the charger cabinet must remain electrically grounded. Disconnect both of
the battery leads and unplug the charger from the AC source before disconnecting any electrical component
or wire. Failure to do so may result in serious bodily injury.
High Voltage. Do not touch the 14-gauge wires and
make sure these two wires do not come into electrical
contact with any other object. Failure to do so may
result in serious bodily injury.
14. Remove the charger cover and perform the following tests:
•
Inspect the internal wiring of the charger and repair as required.
•
Check the continuity of both fuse links and replace if faulty.
•
Disconnect one transformer lead from the capacitor. Test the
capacitor using the capacitor test function of the meter. It is a 6
microfarad capacitor. If the capacitor is bad, it must be replaced.
Stop here and repair the problem.
•
Reconnect the transformer lead to the capacitor and disconnect
one transformer lead from one of the diodes. Test each of the
diodes using the diode test function of your meter. If either one
of the diodes are bad, replace the diode assembly. Stop here and
repair the problem.
15. Reconnect the lead to the diode.
16. Reconnect the charger to the vehicle’s harness and slide
the wiring insulators back into place. Connect the charger
to the AC source and perform the following tests:
•
Test the voltage from the fuse assembly (-) to the diode block
common terminal (+). This voltage should be equal to the battery
voltage. If the voltage is less than the battery voltage, then the
wires from the harness connectors to the charger are bad. Stop
here and repair the problem.
•
Test the voltage across the white and black wires that are
connected to the timer board. This voltage should be the same
as the rated AC voltage of the charger. If the voltage is less
than the rated AC voltage of the charger, then the wires from
the harness connectors to the charger are bad. Stop here and
repair the problem.
•
If the timer relay does not pickup (click) when the AC source
is connected, then the timer control circuit or the relay is bad
(refer to Timer Relay Test). Stop here and repair the problem.
•
Test the AC voltage across the transformer primary circuit.
The transformer primary consists of the two solid wires with
the brown fiber insulator that are connected to the timer board.
This voltage should be the same as the rated AC voltage of the
charger. If the voltage is less than the rated AC voltage of the
charger, then the timer relay is bad. Stop here and repair the
problem.
•
Test the AC voltage across the transformer low voltage
secondary circuit. The transformer low voltage secondary circuit
can be tested at the two solid wires with the brown fiber insulator
that are connected to the anodes on the two diodes. The voltage
here will vary depending on the state of charge in the batteries.
The voltage should be between 208% and 250% of the rated DC
voltage of the charger. If the voltage is not between 208% and
250% of the rated DC voltage of the charger, the transformer
is bad and must be replaced. Stop here and repair the problem.
High Voltage inside the charger. Do not touch any
internal components while the charger is plugged in.
Touching internal components may result in electric
shock causing severe bodily injury or death.