BATTERY AND CHARGER SECTION Cc | CONTENTS PRECAUTIONS AND PREPARATION. Precautions. BATTERY — ‘Trouble Diagnoses and Corrections. Removal, Installation Inspection Battery Maintenance. Storing Battery CHARGER General Specitications. feo How To Charge Battery (JAPAN STORAGE BATTERY CO., LTD. made separate-type) Layout (On-vehicle battery charger)... Circuit Diagram (On-vehicle type) Components (On-vehicle type) Inspecting and Adjusting Charger Measuring No-load Terminal Voltage.. Charging Operation ..... Trouble Diagnoses and Corrections. nS 28 nT 12 12 ei] 18 19PRECAUTIONS AND PREPARATION Precautions WARNING: Do not smoke or place any fire near the battery b viced or handled. © Be careful not to spill electrolyte on your body or clothes as this may cause injury or chemical burns. @ Ifelectrolyte flows out or leaks from the battery case, imme- diately dilute with a neutralizing detergent (such as sodium bicarbonate, calcium hydroxide, etc.) and then rinse with a large amount of running water. Never place any metal objects (such as tools, etc.) on or across battery terminals. This may ignite and explode hydrogen gas emitted from the battery or cause damage to the battery and personal injury. ‘© Static electricity may explode the battery. Do not attempt to wipe or clean the upper surface or terminals of the battery with a dry cloth or do not place a viny! cover over the bat- tery. Always wipe clean the battery case with a wet cloth. CAUTION: © Electrolyte leakage may corrode the battery itself. Always tighten battery vent caps firmly. © Do not allow any one who is unfamiliar with battery handling instructions to inspect the battery. 9 ser BC-2BATTERY See Trouble Diagnoses and Corrections CAUTION: © The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the user's complaints and check the actual vehicle to fully understand under what conditions the symptoms occur. ‘© Request battery maker to replace cells. Trouble Corsition Probable cause Corrective action Ghort-cir | Exiremaly iow cel voltage and spe. | Short-circutes on bottom or sida part | Replace fully col by single charged utes tite gravity during charging. ie ve fo dropping of active mater |" call ‘charging and elecrostate charging | Shortcireutee tue to broken or holed 2, Low gassing during enarging Separator (Warping of platss dus fo 3 Excessive nee of vlectroiyte tempera: | repetition ot averaioharging will fore during emarging, {eelerate such fault) 4, Quick cropping of apecifc gravity | Short-crevited dve to incursion of bro- ‘ior charging on piooes during fabrication of at Gaaton fo 'e Repeliion of overcharging and die [wl the condiion ie im early sage, charging remove the probable cause ad carry 2, Accelerated gassing during charging |« Exponed plates in air for along time | on equation charging. fand specie gravity not rising Yo nore |” uw lo lack of electrolyte fe Replace tauty cell by single charges imal value 1 Careless storage without adetiona! |" col amage cannot be remediea 2. Guick dropping voltage during ais. |” eharging charging (Low battery capaciy) |e Use of battery at excessively high spe 4, Whtenod plates mentveme cases |” oie grav 1 Excessive sell-decharging ave to Excessive |} Guek dropaing of specif gravy |» Use of impure water other tan die [w Take dally care ol battery serra. | aterenarging, tiled water Replace faulty cel by single charges Charging }2.Consizerably reduced charging _| Incursion of impurities ce capacity, [2 Too high specie gravity 2 Elocroive temperature high 2 insu cleaning of container, leak age of Blockee Mula Exchange | Exchange polariy of some celle in@ |» Due fo quick diacharge without note | Replace eel) fopotarty | battery euring dacharging or high |" ing he extremely low capacity oh lective temperature of some cells. | some cals 2, Caused'by emission of gas due to | Lack of necessary preparative moans. | Tako daily care of battery. Gisolving of eeetoryte [o SSch 28 equation charge ones 1. Elscvlyte color changed to brows | Due 10 old battery corroded acive |» Chock ior valaga ang specific gravy faetors Sropped trom tatgued postive plates. |* TrOK. use the battery for the time Sand mized nto electrolyte Dein 12. Smell of chlorine during charging _|# Seawater mixed into electrahyte | @ Replace electrolyte and charge battery Geb chicrine smell reappears 3. Electrolyte excessively reduced |e Cracked battery cals, Je Repiace cals, Excessively high electrolyte tempera- | Fina causes and fellow prope: proce ture during charging cure fe reat, 1 Excessive sulfation Take proper measure tor sullaton. 4, Excessively high electrolyte tempera | Lack of electrolyte eter to each corrective action ‘wre Shorted colle | Reversed polarity '5. Heat Irom connecter portion = Poor contact of connector with binding | Solder (Inquire with batery maker) posts, Battery has reached its life if the following phenomena appear (Also take into account the battery age and operating conditions.) © Electrolyte decreases fast and supplying frequency increases. Electrolyte temperature becomes 50°C (122°F) or more. Timer of charger cannot be turned OFF (or sometimes cannot be turned OFF). There is greater variance in voltage and specific gravity among cells. Electrolyte color changed to brown (emergence of PbO, sediment in electrolyte) Electrolyte color changed to gray (high electrolyte temperature causes Pb sediment and dropping} Specific gravity does not reach 1.250 or more even after charging or equation charging is complete. BC-3BATTERY a Removal CAUTION: © Always use chain block and hoist which can stand battery weight when mounting and removing battery. © Stabilize vehicle body by pulling parking brake lever and fixing stoppers to front and rear wheels before operation. © Always employ a person who has completed a slinging or a hoisting skill course to perform battery hoisting and low- ering work. © Use care not to damage harness of battery cable, etc., bat- tery support and overhead guard when mounting and emoving battery. 1. Remove battery plug. CAUTION: © Do not pull cable when holding battery plug. ¢ Remove battery plug after turning OFF key switch. 2, Remove lock of battery hood, and open the battery hood by clutching grip. 3. Securely fix battery hood by locking device of the battery hood on the right of rear pillar. 4, Remove right side panel. 5. Remove battery drop stopping pin on upper part of battery rear side. BC-4crocs BATTERY Removal (Cont'd) 6. Open lid of battery hood, and disconnect connector of bat- tery liquid level warning 7. Place battery hanger on hoist and lower the hanger from notch of overhead guard. 8. Put hook of battery hanger through battery case, and slowly lift it WARNING: Use extra care with hanger. Never let it make contact with ter- minal of battery when placing it. If contact is made, sparks, leading to burns and explosions occur. 8. Slowly move hoist, and place battery in safe spot BC-5BATTERY installation Battery mounting follows procedure in reverse order of removal. CAUTION: © Confirm mounting direction of battery case. ¢ Mount battery by putting battery case to rear plate and slid- ing it so as not to damage bracket of battery plug and elec- trolyte level warning harness. '* Connect battery electrolyte level warning connector. © Connect battery plug. ‘© Sandwiching of harness causes short and burns of harness, leading to unexpected malfunctions. © Never forget to attach battery drop stopping pin. Inspection WARNING: © Never use fire in a spot for inspecting battery. © Never let battery electrolyte containing dilute sulfuric acid stick to eyes, skins, clothes or the like. It may cause loss of eye sight and burns and holes on clothes. If stuck, was! with a lot of water. If it enters eyes or you drink mistake, wash or drink a lot of water and consult with a doctor as soon as possible. NOTE Inspection of battery voltage can be performed in an interactive diagnosis mode without using tester. Refer to CS section (“INTERACTIVE DIAGNOSIS") MEASURING CELL VOLTAGE NOTE This is useful for determining battery life and condition, Measure voltage of each cell BC-6BATTERY Inspection (Cont'd) EXTERNAL LEAKAGE OF BATTERY ELECTROLYTE (@ leak) Locate leaking cell following the flow chart below. NOTE: Put tester to paint erased portion (paint is erased by file) when putting the tester to iron box. White zinc sulphate crystals are most often stuck to © ter- minal of electrolyte leaking cell. ‘Measure voltages by putting tester © to © terminal of battery plug and tester © to iron box I Remove battery trom vehicle body and wash it with water ® Voltage erated NOTE: For inspection of © leak, measure in reverse polarity of all © and © for @ leak inspection. B Me © terminal of battery plug nal of each cell sure voltages in sequence by pulting tester © to _ | OK (na teak) | is gen ‘Second time and tester @ to @ termi- Find cell close to measured value of @. and tester © to © terminal ————— Measure voltages by putting tester © to iron box cent celis (in serial direction). Select another ceil Is of found cell and adja Gall whose voltage value i toov. is close No _,|[Eteciroivte non- [taking cet Tes leciralyie leaking cell BC-7Lop tater display | Lc symbol display Type A Frost Type 8 @ o Float cron BATTERY Inspection (Cont'd) ELECTROLYTE LEVEL CAUTION: Fill distilled water when battery electrolyte level drops. NOTE: When battery electrolyte level drops, “BAT LIQUID LEVEL DOWN 019" is displayed on LCD letter display on the left of meter panel and wrench mark (me) is displayed on LCD sym- bol display on the right of meter panel 1. For inspection of battery electrolyte level, observe float con- dition from horizontal direction while keeping transparent case closed. If float tip is in between @ - ® in left figure, itis OK. CAUTION: Be careful because battery specifications may vary with each maker. 2. If inspection finds a cell in which electrolyte level is too low, check if there is any leakage and fill with distilled water. Continue filling up with transparent case opened until float rises to ® or © position in left figure. However, be careful, for it may vary with each maker. NOTE: © Probable causes of leakage are as follows: ‘© Damage to transparent case © Excessive filling with distilled water © High electrolyte temperature during charging, leading to electrolyte overtiow CAUTION: © Use care not to fill distilled water excessively. It may cause short or leakage. © Electrolyte lid is pushed into battery cell and needs to be secured to prevent leakage. © If there are any cracks in electrolyte lid, replace with new one. © Be careful because battery specifications may vary with each maker. BC-8Rubber bulb ass cylinder Gave Proper reas gauge indication at eye level ‘Suction tube BATTERY Inspection (Cont'd) ELECTROLYTE TEMPERATURE Measure electrolyte temperature of each battery cell with a thermometer. NOTE: When battery electrolyte temperature rises, electrolyte and capacity of the battery expand. However, specific gravity decreases because there is no change in weight. Contrary when electrolyte temperature drops, specific gravity increases. Thus, when measuring specific gravity, evaluate result by con- verting electrolyte temperature at 20°C (68°F). (Refer to “SPE- CIFIC GRAVITY" section.) SPECIFIC GRAVITY NOTE: Specific gravity is very useful for determining battery life and condition, 1. To measure specific gravity of each battery cell by gravime- ter. CAUTION: Measure with gravimeter placed in battery cell. Use extra care to prevent scattering of battery electrolyte outside when pulling it out of the cell. 2. Keep scale of gravimeter at eye level and read upper end Portion of battery electrolyte swollen due to surface tension CAUTION: © Ifthere is variance in specific gravity among cells, perform equation charging and measure specific gravity again. (For method of equation charging, refer to CS section). If result shows big variance in specific gravity among cells, battery has reached the end of its life. (Battery life depends on years of use, conditions of use and maintenance; equation charging may be necessary several times depending on cases). © If specific gravity is below 1.250 after charging, battery has reached the end of its life. © Carefully determine the battery life based on the above observation, together with advice by battery maker person- nel. BC-9Hysrometer temperature correction chart 220] 1.200} i +1260) 1200) 4.260 1300 1220 Speci gravity at 20°C (68°F) 11.160 a0 (8) en men (48 (OOD Battery clectaive temperature" BCTea2| BATTERY Inspection (Cont'd) 3. When battery electrolyte temperature is other than 20°C (68°F), convert specific gravity into temperature, St + 0.0007 x t- 0.014 : Specific gravity of battery electrolyte at standard tem. perature [20°C] (68°F) Specific gravity of battery electrolyte measured at (C t' : Temperature of battery electrolyte during measuring When specific gravity converted into temperature is below 1.145, immediately perform charging. NOTE: Specific gravity at the time of charging end: 1.280 [electrolyte temperature 20°C (68°F)] Battery Maintenance CLEANING If dust is accumulated on upper suriace of battery, the dust can absorb water and cause leakage between terminals. Periodi- cally clean the upper surface of the battery with a wet cloth and dry it when inspecting electrolyte level. WARNING: © Never clean the upper surface of the battery with a dry cloth, dust it or put a vinyl cover on it. It may generate static elec- tricity and cause battery explosion. © Never pul fingers or driver into battery connection plug. Never touch connection terminal of the battery. It may cause electric shock and short. CAUTION Always clean the battery before charging. BC-10BATTERY Battery Maintenance (Cont'd) SUPPLYING DISTILLED WATER CAUTION: © Fill distilled water up to prescribed level on daily basis, Further, it is recommended that distilled water always be available. ‘© Never mix tap water. It may shorten life because it contains s such as chlorine, Fe and the like. Distilled water is made by using ion exchange resin. Ingredi- ents are as follows’ vem [univ |] ew [won cat Trarepart nd fmpearance [SPELT] | Fe ron) | baow 005% NO, (nitric acid) | below 0.0005% Cu (copper) _| below 0,0005% ‘NH, (ammonia) | below 0.0005% | [Mn (manganese) | below 0.0005% KMnO, (potas- Cci(chlorine) | below 0.0005% | | sium permanga- | below 0.0003% nate) Storing Battery Be sure battery is fully charged before placing it in storage. CAUTION: Before charging, add distilled water so that electrolyte is a lit- tle higher than the prescribed level. @ When not in use, battery should be stored in cool and dark place (well ventilated and temperature and humidity are low). Check specific gravity from time to time and, when it is below 1.200, charge the battery. Perform equation charg- ing once every two months. Battery determines a life of forklift, and thus be sure to record every maintenance work BC-11CHARGER a General Specifications Tae Temas [Manet sate) pu |-oe = Ac nice man | Neenanaed : ; ESR, | le | SHEA Too cumen | Ez] momauren | Th = ose sea | momaaren | es Tagg | ‘this | “eow” | voted a speci “ w ia a ws a z ear t 3 [Ge és ets 100 a 2 cuxzsure | ze = co 0 euesaie |e = a ® 2» cuxasnre | 0 oe = = wo ® [= cuss | @ | an ” “s ° cuca | ‘0 6 = ewan | 2 165, “ “0 CLK-SOHG a 0 “ ¢ ” 400 S ws “ 2 cxawe | har] 1 TAUTION: Make sure plug scheduled to be shipped fits client’s socket. BC-12CHARGER General Spec ations (Cont'd) Diode capacity Fuse capacity Battery plug Plug A (at time of Plug B (at time of ‘ipping) ‘shipping) Socket u SEE | nzconper ab ot00cs-40 ‘Thyee phase ‘Three phase ‘621 wee" | REahs oe Binns xe sn | wom sroae Sgeate | “pum ere a See neat, | ORS? 2ow20 20MA20 aan, Bev asco con 49uK20 hl 7m, 1504, 96v ‘esto Not equipped Battery plug Battery Separate-type batiory charger Breaker screen BC-13CHARGER How To Charge Battery (JAPAN STORAGE BATTERY CO., LTD. made separate-type) ‘nut plug output plug Normal charge 2 |_—cneck ame Pilot lamp. aru |_~ 0k (charge completion) Buten————~ fame |_— Fina! stage lamp Button. Equaton charge | Pad Pilot amp. |— initial stage lamp (2nd) f— Initial stage lamp (139), ‘charge ON-OFF — uton ° Test lamp 1. Ensure the supply side voltage corresponds with the charger input voltage. NOTE: The battery chargers are preset to the following input voltages at the time of delivery: 220V .... 200-volt charger 440V ... 400-volt charger 2. I the charger input voltage does not correspond with the supply voltage, the input side voltage is adjustable as fol- lows using the tap changer located inside the charger. WARNING: Unplug the charger before adjustment. Serious injury or death can occur by electrical shock. BC-14CHARGER How To Charge Battery (Separate-type) (Cont'd) ‘<200-volt charger > Set valve (V) Tap ... 200V, 210V, 220v, 230V ze cont 2] a 210 — i | Po Supply sie voltage) Set value (V) <400-volt charger > Tap ... 340V, 360V, 380V, 400V, 420V, 440V, 460V NOTE: a. On the 200-volt charger, the taps are arranged on the side of the transformer inside the charger, as shown below. Tighten the terminals with a bolt and nut. wo 30 am oO wo 420 AAD at supaly side voltage (¥) b. On the 400-volt charger, the taps are arranged on the side of the transformer inside the charger, as shown below. Tighten the terminals with a bolt and nut. Transtormer WARNING: Before selecting the correct taps for charging the battery, ensure that the input plug (4P) is disconnected. 3. Connect the charger output plug to the battery plug. BC-15,CHARGER How To Charge Battery (JAPAN STORAGE BATTERY CO., LTD. made separate-type) (Cont'd) NOTE: a. Do not connect the charger output plug to the body harness connection. The battery will not charge through this connec tion. b. On the 80A, 100A, 130A and 165A-chargers used with the M02 series, connect the accessory intermediate cable between the battery plug and the charger's output plug. 4. Connect the charger input plug to the wall outlet (in the service shop). CAUTION: To prevent a short circuit, install a no-fuse breaker on the wall outlet side (in the service shop) to connect the charger input plug. 5. Push the NORMAL or EQUAL button to select normal or equalizing charge, respectively When an equalizing charge is desired, press the EQUAL button to set the charger in that mode. The NORMAL pilot amp will go out and the EQUAL pilot lamp will come on, Make sure only the pilot lamp of the selected charging mode is lit At this time, charging will be started automatically. NOTE: a. Push the NORMAL or EQUAL button for about 2 seconds. Do not push it more than 5 seconds. If the button is pushed for extended periods of time, the timer will enter test mode. The test lamp will come on. The test mode will end in 10 seconds to 2 minutes and the test lamp will go oft ‘When the test mode is operating, charging will not start because the charging mode is not selected b. After charging is started, it is not possible to change the charging mode (NORMAL or EQUAL). If it is necessary to change the mode, stop charging (push the STOP button), and then select the charging mode again. ©. It is advisable to charge the battery using the equalize charging mode at least two or three times a month. 6. While charging, the charge indicator lamp will come on sequentially and remain lit. Firstly, the initial (1st) lamp comes on, then the 2nd lamp, and they remain lit. Finally, the Final lamp will come on, NOTE: When the FINAL lamp comes on, the timer will activate 7. When charging has been completed, the charging circuit automatically opens. At this point, the Initial (1st) lamp, 2nd lamp, Final lamp and OK (charge completion) lamp will all come on to indicate that charging has been completed At this time, the charging mode lamp will go out. 8. After ensuring that the Initial (1st and 2nd), Final and OK lamps are on, disconnect the charger output plug from the battery plug. All lamps will then go out NOTE: a. Do not disconnect the input plug while charging is taking place b. Before disconnecting the charger output plug from the bat- tery plug, make sure the Initial (1st and 2nd), Final and OK amps are lit (4 lamps in all) BC-16CHARGER How To Charge Battery (JAPAN STORAGE BATTERY CO., LTD. made separate-type) (Cont'd) WARNING: I the CHECK lamp remains on after charging the battery, the problem may be due to a malfunctioning main timer or an abnormal battery. Immediately contact an authorized NISSAN dealer for inspection. When the charger output plug is disconnected from the bat- tery plug, the CHECK lamp will go out. b. WHILE THE BATTERY IS BEING CHARGED OR IMMEDI- ATELY AFTERWARD, INFLAMMABLE GASES ARE ACTIVELY PRODUCED. BE CAREFUL TO KEEP ANY OPEN FLAME AWAY FROM THE BATTERY. ¢. LEAVE THE BATTERY LID OPEN DURING THE CHARGING PROCESS. d. Keep the parking brake lever engaged during the battery charging process on the truck. @. Before charging the battery, add distilled water up to the upper limit level. Do not overfill. f._ Ia fuse located on the transformer Is blown, replace it with fone of the same type and rating. 9. Periodically clean the caps, removing any foreign matter from gas vents. The caps need not be removed during the charging operation. h. When charging is complete, ascertain with a gravimeter that the specific gravity is 1.28 at a temperature 20°C (68°F). BC-17CHARGER Layout (On-vehicle battery charger) BC-18CHARGER Circuit Diagram (On-vehicle type) BC-19CHARGER Charging (Ac switch) Ac relay / Vehicle sive socket Components (On-vehicle type) VEHICLE BODY SIDE SOCKET (equipped with inhibitor switch) When charging, insert plug into socket for charging input plug, inhibitor switch (AC switch) is actuated and then vehicle body is placed in charging mode. Inspection Inspect diameter of male pin of the socket. Standard value: 8.15 - 8.20 mm (0.3209 - 0.3228 in) CAUTION: Repeated charging reduces space of the male pin of the socket and, when charging input pin is inserted, female pin does not fit so well (space is yielded). As a result, it may generate heat during charging, causing burns of the socket and the plug. NOTE: © tis convenient to use one female pin (new one) on plug side as a gauge. © If fit is not so good, enlarge space of a crack portion of the pin by a flat-bladed screw driver. Inspection of inhibitor switch can be performed in an inter- active diagnosis mode. (Refer to CS section.) AC RELAY, DC RELAY Fixed by machine screw on back side of charger panel on the left of installed frame. Thus, when inspecting these, first remove the charger panel. The charger panel can be removed by loos- ening three bolts. CAUTION: Various pieces of harness are connected to the charger panel. Use care not to damage the harnesses when removal is per- formed. Charger panel mounting torque (for reference) (Bh: 3-7 - 5.0 Nem (0.38 - 0.51 kg-m, 2.7 - 3.7 ft-lb) BC-20'50A, 758, TODA capacity Reset bution acrooae CHARGER ‘Components (On-vehicle type) (Cont'd) AC relay is for detecting ON/OFF of AC power source and also functions as a protection against overcurrent. Inspection Inspect continuity between coll terminals (TH-S1) with a circuit tester. CAUTION: When inspecting coil continulty, be sure to pull out relay con- nector. DC relay is to function opening and closing of magnet switch. It is actuated by pushing FN1 (charging start switch). Inspection Inspect continuity between coil terminals (B-D) with a circuit tester. CAUTION: When inspecting coil continuity, be sure to pull out relay con- nector. PILOT LAMP When charging is started green lamp attached to charger panel turns ON and turns OFF when charging ends. Inspection Inspect valve cut and continuity between terminals. MAGNET SWITCH (equipped with thermal relay) Magnet switch is equipped with thermal relay functions as a protection against overcurrent. When overcurrent is caused to input side for some reasons, the thermal relay is actuated, thereby the magnet switch is opened and charging will stop. When the thermal relay is actuated, find the cause and delete it and then reset it by pushing “reset” button. NOTE: © Electric circuit shorting is a cause for actuation of the ther- mal relay. However, the following causes must also be checked when inspection is performed ‘© Drop in specific gravity and voltage of battery due to exces- sive discharging © Power voltage too high BC-21CHARGER [B0A, TER, GOA capacity hewn ‘Components (On-vehicle type) (Cont'd) Inspection Whether thermal relay is actuated or not, is confirmed by push- ing red check button of the thermal relay. Be sure to push “reset” button after the confirmation. Inspect continuity between terminals with a circuit tester after resetting Between terminals | une | Continuity w ‘Check button | tO y scr2=83] Inspect continuity between terminals by circuit tester while HOA capacity pushing manual button of the magnet switch, anual bution ———_ Faget baton Between terminals OFF time ON time AU No. Yes s—v No. Yes Tw No. Yes Inspect continuity between coil terminals of the magnet switch by circuit tester. ' \ Tap changer Between terminals Continuity 2TH ‘Yes TAP CHANGER Tap changer having a tripolar terminal base is for connecting secondary side terminal of magnet switch and primary side terminal of transformer. For adjusting tap, refer to “Inspecting and Adju CAUTION: Do not confuse phases when connecting the secondary side terminal of the magnet switch and the primary side terminal of the transformer. Make sure there is no slack after connection. NOTE: Same colors should be connected. TRANSFORMER Transformer is for changing power voltages (200V, 400V) so as to be suitable for charging. It is attached under battery case. When it is inspected and attached/detached, first remove the battery case. CAUTION: © Transformer is heavy. Thus, when attaching/detaching it, use hoist or crane for safe operation. © Always employ a person who has completed a slin: a hoisting course perform hoisting or crane operation. 9 or BC-22secondary cide CHARGER Components (On-vehicle type) (Cont'd) Inspection Using circuit tester check continuity between primary and sec- ondary side terminals to check coil continuity. NOTE: When inspecting transformer, inspection of the primary side on the tap terminal base and the secondary side on the diode input, side in on-vehicle state can also be performed. DIODE ASSEMBLY Diode assembly is for rectifying AC generated on the second- ary side of transformer to DC. Diode assembly having capacities of SA, 75A and 100A is attached to the left side of counter weight via aluminum plate. This is a module type diode having 6 diodes within one pack- age. Diode assembly having capacities of 120A and 150A is fitted in motor room on the left side of vehicle body with aluminum plate ‘One package includes two diodes and three packages are used. BC-23CHARGER ‘Components (On-vehicle type) (Cont'd) Inspection ATER TR ay Fy NSU. Pe a zt Hel} iy | “20A, 150A capaci, 7 La Remove diode assembly and inspect conductivity between ter- minals CAUTION: When removing diode assembly, turn OFF AC power and key y “ switch and make sure battery plug has been pulled out. Black | Rea Measuring point | PME | Fee | Analogue tester resistance (2) , ) Re x Tw Continuity | scroos ‘ m [x = Diode assembly GOR, TSA {005 Capasiny y | Continuity | vec) (coral an e z I Contino on oo iy mz = poet | a x~O of Continuity | y [6 a yx @ [yy Continuity z [0 a z~ oO [| 2 Continuity NOTE: Use tester in" 1" (Q) range. CAUTION: Heat generated by diode is radiated through aluminum plate to vehicle body. Thus, before attaching the diode, remove dust from the radiated face of back side and coat it with heat radiat- ing silicone-based grease (Shinetsu Silicone Grease or equiv- alent). Diode (50A, 75A, 100A in capacity) (for reference): Diode to aluminum plate 5 = 2.0 Nem (0.15 - 0.20 kg-m, 1.1 - 1.4 ft-lb) Cable (0): 1.5 - 2.0 Nem (0.15 - 0.20 kg-m, 1.1 - 1.4 ft-lb) Diode (120A, 150A in capacity) (for reference): Diode to aluminum plate (O): 1.5 - 2.0 Nem (0.15 - 0.20 kg-m, 1.1 - 1.4 ft-lb) Cable (OE: 1.5 = 2.0 Nem (0.45 - 0.20 kg-m, 1.1 = 1.4 f-lb) Bus bar (Oy: 5-1 - 6.5 Nem (0.52 - 0.66 kg-m, 3.8 - 4.8 ft-lb) Diode assembly 1 = 6.5 Nem (0.52 - 0.66 kg-m, 3.8 - 4.8 ft-lb)CHARGER ‘Components (On-vehicle type) (Cont'd) CHARGER TIMER Charger timer is incorporated in meter printed board of meter panel. Inspection of main-timer and back-up timer is performed in an interactive diagnosis mode. (Refer to CS section.) Inspecting and Adjusting Charger INSPECTION Measure insulating resistances by circuit tester as follows: Measuring point ‘Measured value ‘Between respective terminals of fap changer and ogy ey dover 00 Between X, Y and Z terminals of diode part and body ‘Between grounding pin of socket and body on When insulating resistances are less than 100 k®, blow air to transformer, magnet switch and diode part and clean these with a dry cloth ADJUSTMENT Four types (200V, 210V, 220V and 230V) of taps are set depend- ing on voltages on power source side. Improper adjustment of the taps may cause overcharging or charging shortage. In a spot charged for the first time, be sure to check power and voltage during charging and see if the taps are set properly. In addition, the tap set at time of delivery from factory is 210V. 1. Measure socket voltage on power source side. Then, by inserting charging AC cable, measure voltage on the power source side by means of vehicle body side plug. CAUTION: ‘© Do not measure voltages between U, V and W phases and ground. © Adjust measuring time according to client's charging time. Voltage may decline in the daytime. BC-25CHARGER Inspecting and Adjusting Charger (Cont'd) 2. Select suitable tap based on measured voltage and attach it (Tap voltage is displayed on terminal.) Vinyl ea eer Vehicle side battery 9145, Tupsoncion [a | 0 | mo [m0 ower source size | agg | ao; -210 | 211-200 | zat- voltage (V) l NOTE: ‘Terminal for 230V is fixed on transformer portion. Thus, remove battery and connect the terminal by using different wiring. CAUTION: @ Make sure the terminal is firmly fixed after connection. After connection, make sure crimp type terminal not con- nected to tap changer is covered by a vinyl cap and securely insulated. Measuring No-load Terminal Voltage After tap adjustment, measure noncharged terminal voltage and confirm if charging is performed properly. 1. Remove battery plug, connect AC plug to socket on power source side and turn power ON to be prepared for charging. 2. Connect circuit tester to battery plug on vehicle body side. 3, Measure voltages by pressing manual button of magnet switch. Standard value (for referenct Approx. 73V (battery rated voltage 48V) CAUTION: When pressing the manual button of the magnet switch, be sure to check if you can hear buzzing sound of the transformé BC-26CHARGER Ee E Charging Operation For charging operation, refer to CS section Trouble Diagnoses and Corrections For charger trouble diagnoses and corrections, refer to CS sec- tion (“TROUBLE DIAGNOSES FOR CHARGING SYSTEM”) BC-27