ELECTRICVEHICLE-BATTERYCHARGERChargerTroubleshooting
15
HIGH-FREQUENCYBATTERYCHARGERTROUBLESHOOTINGGUIDE
1.Erroneousevent
(anunknownvariable;
somethingoccurredto
thechargerorvehiclethat
wasnotthefaultofeither)
Resetchargerpower.SeeResettingPower–External
Chargeronpage15-13.ReconnectDCcordtovehicle.
Ifstatusgoesaway,continueusingcharger.
2.Batteryhighvoltage
Ensurebatterysetisrated48voltsandcomposedof24cells.
SeeBatteryVoltageUsingMultimeteronpage15-16.Ifnot,
replacewithcorrectbatteryset.Resetchargerpower.See
ResettingPower–ExternalChargeronpage15-13.
3.Batterylowvoltage
Ensurebatterysetisrated48voltsandcomposedof24cells.
Also,checkthevoltageofeachindividualbattery.SeeBattery
VoltageUsingMultimeteronpage15-16.Ifnot,replace
withcorrectbatteryset.Resetchargerpower.SeeResetting
Power–ExternalChargeronpage15-13.
4.Chargetimeout
causedbybatterypack
notreachingrequired
voltage.
Checkforlooseorcorrodedconnections.Checkforoldor
defectivebatteries.SeeTestProceduresonpage15-16.
5.Badbatterypack
Testbatterypackhealth.Lookforshortedordamagedcells.
SeeBatteryConditionUsingChargeronpage15-16.See
alsoElectricVehicle-Batteriesonpage14-1.
6.ACvoltage
out-of-range
TestandinspectincomingACpower.SeeACPowerand
ContinuityTestofACCircuitonpage15-17.
7.Ambienttemperature
toohot(above104
°F(40°C))
Checkfordirty,obstructed,ordamagedcoolingns.Clean
ifnecessaryandensuresufcientcoolingairow.Chargers
stackedontopoforlocatedtooclosetoeachother.Move
chargersfartherapart.Ifissuecontinues,waitforambient
temperaturetocoolorrelocatechargertoacoolerenvironment.
8.Ambienttemperature
toocold(below-40
°F(-40°C))
Waitforambienttemperaturetowarmorrelocate
chargertoawarmerenvironment.
9.BadDCconnection
Inspectchargerreceptacle,receptacleharnessconnections
andDCcordconnectiontocharger.SeeDCPlugand
Receptacleonpage15-16.SeeChargerDCCircuit
ContinuityTestonpage15-17.
Flashing
orange
Chargerunableto
completecharge.
(Usuallynot
relatedtocharger
itself.Something
occurredtoprevent
thechargerfrom
completingthe
charge.Check
externalfactors
rst.)
10.Corrodedorloose
connections
Cleanortightenconnections.
1.Chargerabnormality
Resetchargerpower.SeeResettingPower–External
Chargeronpage15-13.ReconnectDCcordtovehicle.
Ifstatusgoesaway,proceedtochargeagain.See
ChargerOutputTestonpage15-18.
Ifstatusoccursagainduringthenextchargecycle,attemptto
chargewithanotheridenticalcharger.Ifchargeissuccessful,
proceedtostep2.Ifstatusoccursagain,troubleshootthe
ACpowersupply,vehicleandbatterypack.
SolidredChargererror
2.Chargerinternalfault
Replacecharger.
2019PrecedentVillager2MaintenanceandServiceManualPage15-15