DISASSEMBLY-INSPECTION-REASSEMBLY
2 Inspection
DisassemblyProcedure
Note:
Put a tag indicating the connecting position at the time of disassembly to prevent in correct
connection at the time of reassembly.
Remove the charger cover.
Carry out inspection before disassembly. [Point 11
Remove the magnet switch ASSY (MSch). [Point 21
Remove the timer ASSY (AMT).
Remove the resistor (RlaR2). (For 72 V series and 36 V series)
Remove the fuse (Fch). [Point 41
Remove the diode (Dch). [Point 51
Remove the transformer (TF). [Point 31
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operation
[Point I]
Inspection:
lnspect the magnet switch contact continuity.
Circuit tester range R x l
Measuring terminals T-W, S-V and R-U
ON on
Switch
OFF an
Inspection:
lnspect the magnet switch coil continuity.
Resistance between A1 and A2 Circuit tester range
See the Service Standards list. R x l
Inspection:
lnspect the thermal relay contact continuity.
Circuit tester range R x l
Measuring terminals 95-96
Not operated OR
Switch
Operated state mi2
Note:
Do not adjust the thermal relay operating current.
If the thermal relay is operated to stop charging while
the charger is in use, always check the cause of ther-
mal relay operation, and reset the thermal relay after
taking the remedial action.
Push the reset lever lightly to reset the thermal relay.
Inspection:
lnspect the transformer insulation resistance.
Measuring terminals Between each winding and frame
Standard value 0.2 M a or more
Inspection:
lnspect the transformer continuity
Circuit test range R x l
Primary side
u14 1
Vl-w,
W,-U,
Measuring terminals
Secondary side
u2-v2
v2-w2
w2-"2
Standard value OR
[Point 21
Inspection:
lnspect the magnet switch contact continuity.
Circuit tester range fix1
Measuring terminals T-W, S-V and R-U
ON OR
Switch
OFF ooR
Inspection:
lnspect the magnet switch coil continuity.
Resistance between A1 and A2 Circuit tester range
See the Service Standards list. ~ x l
Inspection:
lnspect the thermal relay contact continuity.
Circuit tester range R x l
Measuring terminals 95-96
Not operated OR
Switch
In operated state ooR
Note:
Do not adjust the thermal relay operating current.
If the thermal relay is operated to stop charging while
the charger is in use, always check the cause of ther-
mal relay operation, and reset the thermal relay after
taking the remedial action.
Push the reset lever lightly to reset the thermal relay.
Reset Lever
[Point 31
Inspection:
lnspect the transformer insulation.
Measuring terminals Between each winding and frame
Standard value 0.2 MQ or more
Inspection:
lnspect the transformer winding continuity.
Primary winding
Circuit tester range Q x l
u -v1
1
Measuring terminals v~-W~
Wl-ul
Standard value OQ
Secondary winding
Circuit tester range ax1
u*-v2
Measuring terminals v?"~
""2-Uz
Standard value On
[Point 41
Inspection:
lnspect the fuse continuity.
Standard: 0 i2
[Point 51
Inspection:
lnspect the diode in installed state on the fin. Remove it
only when an abnormality is found.
Circuit tester range RxlK
Measuring Forward Anode @ - cathode @
terminals Reverse Anode @ - cathode @
Forward See the Service Standards list.
Standard value
Reverse on
Installation:
As two diodes having different polarities are used, install in
the correct direction.
Caution:
In the case of the charger for batteries with the capacity
at 320 AH15 HR or less, the diode mounting direction is
the reverse that shown in the figure.
Inspection after Reassembly
1. lnspect each wiring for correctness.
Note:
Check correct wiring at each part by referring to the
charger wiring diagram.
2. lnspect the transformer insulation resistance.
Measuring terminals Between each winding and frame
Standard value 0.2 MQ or more
3. Measure the no-load secondary voltage.
Connect the charger plug to the charger receptacle and
start the timer.
AC voltage
Circuit tester range AC 250 WAC 500 V
"2-"2
Measuring terminals v2-w2
w2-"2
Standard value See the Service Standards list.
DC voltage
Circuit tester range DC 250 V
Both terminals of charger plug
Measuring terminals @terminal - probe @
@terminal - probe @
Standard value See the Service Standards list.
SERVICE STANDARDS
ltern Service Standard
For 200 V -
200 230
Power supply voltage
For400V -
340 460
SG3-35-60JBY-2 Approx. 28
SG3-35-85JBY-2 Approx. 28
SG3-52-120JBY-2 Approx. 42
SG3-52-165JBY-2 Approx. 42
No-load secondary voltage SG3-69-45JBY-2 Approx. 56
(The values are the same for 200 V and
SG3-69-60JBY-2 Approx. 55
400 V.)
SG3-69-80JBY-2 Approx. 57
AC V
SG3-69-1OOJBY-2 Approx. 58
SG3-69-130JBY-2 Approx. 56
SG3-69-165JBY-2 Approx. 58
SG3-115-80JBY-2 Approx. 94
SG3-100-1OOJBY-2 Approx. 85
SG-100-130JBY-2 Approx. 85
Battery for 24 V Approx. 37
Battery for 36 V Approx. 56
No-load secondary voltage DC V
Battery for 48 V -
74 78
Battery for 80 V Approx. 127
CLK-15JT For 200 V: 1300 For 400 V: 5700
MSch coil resistance R CLK-26JT For 200 V: 900 For 400 V: 3900
CLK-35JT For 200 V: 390 For 400 V: 1600
CLK-50JT For 200 V: 390 For 400 V: 1600
Dch resistance in forward R Approx. 25
Dch resistance in reverse Q c*)
SKR71.SKN71102,04 4 (40) [2.89]
20M3020MA30 2.35 (24) [ I ,741
Dch tightening torque N.m (kg-cm) [ft-lbfl SKRI 30SKN130102 10 (100) [7.23]
45M20.45MA20 16.7 (170) [12.3]
SKR240-SKN240102 30 (300) [2 1.71
Insulation resistance (500 V Megger) MQ 0.2 or more
TIMER TEST
1. Main timer inspection
(1) Turn on the AC power switch.
(2) Disconnect the battery plug.
(to unload the charger and operate the voltage relay).
(3) Close the magnet switch (MSch) forcibly by using an insulating bar and keep pressing the NOR-
MAL, switch (black-blue) or EQUAL switch (black-blue) for 5 seconds or more. When the TEST
lamp (red) and CHARGING PROGRESS indicator lamps (three lamps excluding the uppermost
one) come on. Release the switch as soon as they come on, and measure with a stop watch the
time until the uppermost lamp comes on.
(4) If the time until UP lamp lighting after TEST lamp on is as follows and if all lamps go off immediately
after that, the main timer is normal.
When NORMAL switch is pressed: UP lamp on about 6 seconds later
When EQUAL switch is pressed: UP lamp on about 18 seconds later
2. Total timer inspection
(1) Turn on the POWER switch.
(2) Connect the battery in discharged state
(as the main timer is operated first because of voltage relay operation in the fully charged state).
(3) When the NORMAL or EQUAL switch is kept pressed for 5 seconds, the TEST lamp comes on the
start charging. Release the switch upon TEST lamp on and measure the time until CHECK lamp
on with a stop watch.
(4) The total timer is normal if the time after TEST lamp on until CHECK lamp on is as follows.
(The UP lamp does not come on.)
CHECK lamp ON in 90 to 100 seconds.
(5) The lamp goes off when the battery plug is disconnected.
Caution:
If the CHARGE ONIOFF switch is pressed when a fully charged battery is connected, the main
timer operates first to light the UP lamp and not the CHECK lamp. This does not indicate a total
timer defect. Inspect again as described above after replacing the battery with a discharged one.
