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MAINTENANCE PROCEDURE
ERROR CODES
If the display panel on the black box is flickering between –1 and 2 you have a fault in the
transformer or the black box.
Check the two output fuses under the terminal cover. The black box or the transformer
contains no user replaceable parts. Opening the black box apart from the terminal cover
shown will invalidate the warranty. If the Time Out Light comes on you have possibly a faulty
battery. Check each cell with a hydrometer. The Time Out light will come on and the charger
will switch off if gassing level has not been reached in 24hours.
Reverse Polarity Light will light if the output cables to the battery are reversed. Red Cable
Must go to + battery terminal, Black Cable must go to - battery terminal.
CHARGING TIMES
The charger will recharge 2/3 discharged batteries in 8 to 10 hours. In reality batteries are
often discharged more than 2/3 when used on a access platform. The operator tend to use
the machine until the motor stops (This causes arcing of the motor contactor, and severe
heat rise in the motor. Both of which shortens the components life considerably.) Then he
forgets to put the machine back on charge until after the weekend. The result is that the
battery can be as much as 95% discharge before the charger is connected (this causes
severe reduction in battery life).
If the battery cell voltage is below 1 volt the charger may not start. In that case, hold down
the low voltage start button for several seconds. This will bypass the charger safety system
and cause it to start irrespective of battery voltage. After the voltage has increased
sufficiently for the controller to take over, you can let go of the button.
If gassing level is not reached in 24hours the charger will switch off and the Time Out Light
will come on.
Disconnecting the input lead will automatically re-set the timer. Take care not to disconnect
the charger during a charging cycle. Always let the charger reach “Charge Complete” or
“Time Out” to prevent overcharging.
PRACTICAL APPLICATIONS
The operator will run the batteries all the way down. Then he will try to connect the charger
and continue working the machine. This will not work. The electric motor requires as much as
3 times the charger output. The charger will float on max 30A and the motor will not turn
(This results in damage to the motor and contactor)
If the user has a very hectic work schedule he may run out of battery power before he has
finished his work. In that case he can connect the charger to a mains supply before the
batteries are 50% discharged. This will then give enough time for the charger to keep topping
up the batteries and extend the duty cycle of the machine considerably.
The battery life may be slightly reduced as the optimum charging cycle for any battery is
“fully charged - 2/3 discharged and then fully charged”
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