Troubleshooting; Test Equipment Required For Troubleshooting; Important Notes And Instructions; Test Charger Operation - Taylor-Dunn SS-025-34 Operation, Maintenance, And Replacement Parts Manual

Battery Charger

TROUBLESHOOTING

Test Equipment Required for Troubleshooting

Digital Multi-Meter.
Clamp on DC Ammeter to measure up to 20 Amps.

Important Notes and Instructions

• This troubleshooting guide assumes a familiarity with
the use of a digital multi-meter including, voltage tests,
continuity tests and diode testing. If not familiar with any
part of these tests, refer testing to a qualified technician.
• Make sure that the AC electrical socket the charger is
plugged into is in good working condition.
• Make sure that the AC voltage at the electrical socket is
the same as the AC voltage on the charger nameplate.
• Make sure the batteries are in good condition.
• If the charger exhibits intermittent problems, it must be in
the failed mode for troubleshooting.
• There are no internally serviceable components in the
charger. If the charger has failed then it must be replaced.

Test charger operation:

Connect a DC volt meter to the main battery positive and
negative terminals.
Attach a clamp on DC Ammeter to one of the charger DC
output wires.
Plug the charger into an AC outlet.
Wait for charger to start (up to 15 seconds), the ammeter should
display the DC Amp rating of the charger (plus or minus 10%)
indicating that the charger is on (constant current mode).
The ammeter should continue to display the DC Amp rating of
the charger until the battery voltage equals 2.55 VPC. When the
battery voltage equals 2.55 VPC the charger will switch to the
constant voltage mode. At this point the charging current will be
reduced and will taper off until the batteries are fully charged.
This charger is rated for 115 VAC or 230 VAC
operation. When switching from one input voltage
to the other, wait until all three status LED's are
off. Switching voltage when any of the LED's are
on will result in damage to the charger.
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Charger does not turn on:

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.
5. Disconnect the charger from the AC source.
6. Remove the charger end cap where the DC wires enter.
7. Test the voltage across the Battery Positive (red) and
Battery Negative (black) wires at the lower left of the
charger circuit board. This voltage should be equal to
the battery voltage. If the voltage is less than the battery
voltage, then the wires to the batteries have been damaged.
Stop here and repair the problem.
8. Reinstall the charger end cap where the DC wires enter.
9. Remove the charger end cap where the AC wires enter.
10. Test the continuity of all three AC wires from the circuit
board to the AC plug. If you find an open circuit in any
one of the three wires then the AC cord or plug has been
damaged. Stop here and repair the problem.
11. Install the charger end cap where the AC wires enter.
• If both the AC and DC tests are good then the charger has
failed. There are no internally serviceable components
in the charger. If the charger has failed then it must be
replaced.