Service Manual Instruction Manual

SECTION 2 - SERVICE PROCEDURES
3120782 – JLG Lift – 2-9
2.5 BATTERY CHARGER - ASSEMBLY AND
DISASSEMBLY
General Information
DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER
IF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT-
TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY
WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY
REQUEST A REPLACEMENT CHARGER FROM THE FACTORY.
ALSO BEFORE REPLACING ANY COMPONENT, USE THE
CHARGER MANUFACTURERS (SCR) BATTERY CHARGER MAN-
UAL INCLUDED WITH THE MACHINE FOR CHECKING THE INTER-
NAL AC AND DC CIRCUITS TO DETERMINE WHICH COMPONENT
HAS FAILED. COMPLETE WIRING DIAGRAMS PERTAINING TO
YOUR MODEL CHARGER ARE ALSO INCLUDED IN THE MANU-
FACTURERS (SCR) BATTERY CHARGER MANUAL.
The EL Series dual AC input battery charger allows for
replacement of the following internal components. Con-
sult your Illustrated Parts Manual for part numbers of
these components which are available from the JLG Parts
Department:
• Transformer
• Printed Circuit Board
• Shunt Assembly
• Interlock Relay
• SCR Rectifier
• AC Circuit Breaker
• DC Circuit Breaker
Replacement and troubleshooting of these components
requires removal of the battery charger from it’s mounting
on the charger/battery box assembly.
Battery Charger Removal
1. If plugged in, unplug the AC voltage cord from AC
receptacle and remove the charger/battery box unit
from the machine.
2. Disconnect the + (RED) and – (BLACK) charging
wires from the charger to the battery terminals in the
lower battery compartment.
3. Remove the four (4) mounting bolts and washers
located on the back of the upper battery box sec-
tion, securing the charger into the upper section.
4. Remove the charger through the front opening while
pulling the charging wires (RED/BLACK) through the
hole on the bottom of the upper battery box section.
Cover Removal
5. Remove the ten (10) screws on the sides and top of
the charger cover and remove cover.
Transformer Replacement
1. Disconnect the wiring connecting the transformer to
other components within the charger assembly.
2. Remove the four nuts from the cap screws securing
the transformer brackets to the base of the charger
chassis.
3. Remove transformer.