Charger Troubleshooting; General - Yale 524150797 Maintenance Manual

2240 YRM 1890
CAUTION
The charger comes factory set to the battery
installed at the factory and must be changed if
using different batteries. Using an improper
charger mode for your battery pack may cause
severe damage to batteries or charger. Refer to
Charger Mode/Battery Type Selection in this
section to verify the proper mode setting for your
battery pack.
Following the start-up flashing of the LEDs, the red,
POWER ON, LED will illuminate to indicate AC power
is applied to the charger and will begin the charging
cycle.
The charger uses a 5-Step charging process:
Pre-Qualification Test.
1
During this step, the yellow, CHARGING, LED
will flash on and off every two seconds. The
charger is checking for faults prior to the start of
charging. Depending on the condition and state
of charge of the batteries, this step may take up
to 1 minute.
Regulating Current.
2
During this step, the charger will be regulating
current to the batteries and will be operating at
full rated output. The yellow, CHARGING, LED
will be constantly illuminated during this step.
Regulating Voltage
3
During this step, the charger will be regulating
voltage to the
CHARGING, LED will remain illuminated. When
the batteries have reached 80 to 90 percent of
full charge, the yellow, CHARGING, and the
green, CHARGED, LEDs will be illuminated.
Charge Complete.
4
During this step, the green, CHARGED, LED
will remain illuminated. AC power can now be
disconnected from the charger.
NOTE: If the charger noted an abnormal charge
condition during the charging, the charger will attempt
to shutdown and will flash one or all three of the red
LEDs on the top of the charger. If this condition occurs,
see Troubleshooting in this section.
Operating temperature range for the charger is
-10 to 55°C (14 to 131°F). If charger is below or above
indicated temperatures, move lift truck to an area
where charger can return to the correct operating
temperature range.
batteries. The yellow,
Charging and Troubleshooting

CHARGER TROUBLESHOOTING

General

NOTE: The charger runs a pre-qualifying test (yellow
charging light flashing) at the beginning of the charge
cycle to determine the condition of the battery. This
test may take up to 1 minute. After the test is
complete, the charger should begin charging (yellow
charging light continuous) or may display an Error
Mode by flashing one or more of the red LEDs. If an
Error Mode is displayed, stop the general
troubleshooting and follow the chart and procedures in
Error Modes in this section.
1. Check AC power supply to charger:
a. Connect the charger plug to a 120 volt AC
power source using a 20 amp rated extension
cord.
b. Do all 5 LEDs simultaneously flash at least
once upon connection?
(1) YES: Proceed to Step (2).
(2) NO: Check AC power supply to charger and
batter power between B(+) and B(-)
terminals. E/F Series chargers require more
than 12 volts battery power to be operate. If
battery is not ON, or is below 12 volts,
inspect battery. Proceed to Step (1).
2. Check that the charger is configured for the
proper battery mode/type:
a. What is the proper charger mode for the type
batteries being used?
(1) Refer to Changing Mode Setting .
b. What mode is the charger currently set on?
(1) Connect the charger plug to a 120 volt AC
power source using a 20 amp rated
extension cord.
(2) How many times do all 5 LEDs flash upon
connection?
c. Is the charger currently set to the proper mode
for the battery type being used?
(1) YES: Proceed to Step 3.
9