PART 4
Page 122
DC CONTROL
SECTION 4.4
DIAGNOSTIC TESTS
TEST 67 - CHECK BATTERY CHARGE RELAY
(BCR)
DISCUSSION:
The battery charge relay is used to switch the AC
source delivered to the battery charger. When the
BCR is de-energized, the Normally Closed (NC) con-
tacts deliver AC power from the transformer. When
the BCR is energized by Wire 14, the Normally Open
(NO) contacts close and battery charge winding AC
source is delivered to the battery charger.
PROCEDURE:
1. See Figure 38. Disconnect all wires from the battery
charge relay, to prevent interaction.
2. Set a VOM to its “R x 1” scale and zero the meter.
3. Follow the chart below and test each set of contacts.
Connect the VOM test leads to the relay terminals indi-
cated in the chart provided below.
4. To energize or de-energize the relay. Connect a jump-
er wire to a positive (+)12 VDC source and to relay
Terminal “A”. Connect a jumper wire to the nega-
tive (-)12 VDC source and to relay Terminal “B”. The
relay will ENERGIZE. Disconnect the positive jumper
from Terminal “A” of the relay and the relay will DE-
ENERGIZE.
CONNECT VOM TEST
LEADS ACROSS
DESIRED METER READING
ENERGIZED DE-ENERGIZED
Terminals 6 and 9 Continuity Infinity
Terminals 3 and 9 Infinity Continuity
Terminals 4 and 7 Continuity Infinity
Terminals 1 and 7 Infinity Continuity
RESULTS:
1. Replace the battery charge relay if it fails any of the
steps in this chart.
2. If the BCR tests good, but still does not function during
generator operation, check Wire 14 and Wire 0 con-
nected to the BCR.
a.Set a VOM to measure DC volts. Disconnect
Wire 14 from BCR Terminal “A”. Connect the
positive (+) test lead to Wire 14. Connect the
negative (-) test lead to a clean frame ground.
Set the AUTO-OFF-MANUAL switch to
MANUAL. Battery voltage should be measured.
If battery voltage is not measured, repair or
replace Wire 14 between the BCR and the 4-tab
terminal block.
b. If voltage was measured in “a”, set the VOM to
measure resistance. Disconnect Wire 0 from
BCR Terminal “B”. Connect one test lead to Wire
0. Connect the other test lead to a clean frame
ground. CONTINUITY should be measured.
If CONTINUITY was not measured, repair or
replace Wire 0 between the BCR and the ground
terminal.
TEST 68 - CHECK BATTERY CHARGE
WINDING HARNESS
DISCUSSION:
This test will check the continuity of Wire 66 and Wire 77
between C2 Connector and the battery charge relay.
PROCEDURE:
1. Disconnect C2 Connector from the side of the control
panel. The C2 Connector is the closest to the back
panel (see Figure 9, Section 6.1).
2. Disconnect Wire 66 from Terminal 6, and Wire 77 from
Terminal 4 of the BCR.
3. Set a VOM to measure resistance.
4
8
5
7
6
1
FEMALE SIDEMALE SIDE
2
3
4
8
5
7
6
1
2
3
Figure 39. C2 Connector Pin Locations
4. Connect one meter test lead to the male side C2
Connector Pin Location 1 (Wire 77). Connect the
other test lead to the end of Wire 77 which was previ-
ously removed from the BCR. CONTINUITY should
be measured.
5. Connect one meter test lead to the male side C2
Connector Pin Location 2 (Wire 66). Connect the
other test lead to the end of Wire 66 which was previ-
ously removed from the BCR. CONTINUITY should
be measured.
RESULTS:
If CONTINUITY was not measured in Step 4 or Step
5, repair or replace defective wiring between C2
Connector and the battery charge relay.
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