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Troubleshooting
DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components,
turn OFF and remove fuses of disconnect switch (supplying AC power to charger),
disconnect battery, and check for voltage on capacitors. Discharge through insulated
screwdriver if there is any reading.
CAUTION: HIGH VOLTAGE FROM TEST EQUIPMENT can damage silicon diodes and other
parts. Short silicon diodes with extremely short leads, or disconnect, before applying voltage
from a "megger" or other high voltage test equipment.
The following chart contains information which can be used to diagnose and correct unsatisfactory operation
or failure of various components of the unit. Each malfunction is followed by a suggested checking or inspection
procedure. Refer to Connection/Schematic Diagram in the Diagrams chapter included in this manual.
No charging current (Ammeter reads zero)
Check line voltage.
Close fused disconnect switch or repair open circuit.
Check for proper line voltage.
Refer to Line Voltage Changeover instructions in Installation chapter.
Check for blown fuses.
Replace blown fuses. See Table 4-1 for proper fuse sizes.
Check for internal short circuit (diode, winding, wiring).
Repair short circuit, or replace faulty component.
Check for "open" battery circuit.
Clean and tighten connections, especially battery cable connections.
Check Charge Control.
Connect a jumper from the red-white lead of Control Transformer T1 to the red
lead of Contactor K1 coil. If charger starts and ammeter shows charging current
when a battery is connected, check further for faulty printed circuit card on control
and replace as necessary.
Check output circuit fuses. If fuse has blown, check for problem causing fuse to blow.
a. Reverse battery connections, if polarity is wrong.
b. Determine whether a diode is shorted. Refer to Silicon Diode Testing in Maintenance
chapter.
Low charging current at beginning of cycle (battery fully discharged)
Check for failed capacitor (s) (one or more).
November 17, 2020
Troubleshooting Guide
193111-050
MAINTENANCE
6-3
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