Nilfisk-Advance 56395101, 56372947, 56206981, 56388109, 56388120 Service Manual

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 45

Revised 8/00 Form Number 56041170

Battery Chargers

SERVICE MANUAL / PARTS LIST

AUTOMATIC Advance MODELS 56206980, 56206981, 56372947, 56388109, 56395101, 56388502, 56388120, 56409494, 56411058, 56411643, 56409788, 56205983, 56412272, 56206973, 56372203, 56372190, 56388119 Lester MODELS 56031407, 56632342, 56638431, 56638436, 56638439, 56638440, 56632293, 56031403, 56031405, 56031408 MANUAL MODELS (obsolete) 56206975, 56372945, 56372955

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 1

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TABLE OF CONTENTS

Safety ......................................................................................................................... 2

General Information.................................................................................................... 3

Transformer / Rectifier or Power Section.................................................................... 3

On / Off Control Section ............................................................................................. 4

Automatic and Manual Timer Battery Charger Troubleshooting................................. 5

Manual Charger PN 56206975................................................................................. 16

Automatic Chargers PN 56206980........................................................................... 17

Manual Charger PN 56372945................................................................................. 18

Automatic Charger PN 56372947............................................................................. 19

Automatic Charger PN 56388109............................................................................. 20

Manual Charger PN 56372955................................................................................. 21

Automatic Charger PN 56395101 (replaces PN’s 56372947 & 56395347).............. 22

Automatic Charger PN 56388502............................................................................. 23

Automatic Charger PN 56388120............................................................................. 24

Automatic Charger PN 56409494............................................................................. 25

Automatic Charger PN 56411058 ............................................................................. 26

Automatic Charger PN 56411643 ............................................................................. 27

Automatic Charger PN 56409788............................................................................. 28

Automatic Charger PN 56205983 (replaces PN 56206981)..................................... 29

Automatic Charger PN 56412272............................................................................. 30

Automatic Charger PN 56206973............................................................................. 31

Automatic Charger PN 56372203............................................................................. 32

Automatic Charger PN 56372190............................................................................. 33

Automatic Charger PN 56388119 ............................................................................. 34

Automatic Charger PN 56031407............................................................................. 35

Automatic Charger PN 56632342............................................................................. 36

Automatic Charger PN 56638431............................................................................. 37

Automatic Charger PN 56638436............................................................................. 38

Automatic Charger PN 56638439............................................................................. 39

Automatic Charger PN 56638440............................................................................. 40

Automatic Charger PN 56632293............................................................................. 41

Automatic Charger PN 56031403............................................................................. 42

Automatic Charger PN 56031405............................................................................. 43

Automatic Charger PN 56031408............................................................................. 44

BATTERY CHARGER SERVICE MANUAL / PARTS LIST

revised 8/00

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2 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

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SYMBOLS

Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary steps to protect personnel and property.

DANGER!

Is used to warn of immediate hazards that will cause severe personal injury or death.

WARNING!

Is used to call attention to a situation that could cause severe personal injury.

CAUTION!

Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.

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GENERAL SAFETY INSTRUCTIONS

DANGER!

HIGH VOLTAGE! With the charger on, the internal charger capacitor voltage is approximately 650 volts.

WARNING!

Do not operate the charger if it is malfunctioning. Personal injury or property damage could result.

Remove all jewelry when working near electrical components.

CAUTION!

To be able to use the troubleshooting guide safely and effectively it is important to read this manual completely before beginning any tests.

Incorrect assembly may result in a risk of electric shock or fire.

Always unplug the electrical cords, first from the AC outlet and then from the charger receptacle before attempting any repairs or service to the charger.

REPAIRS BY QUALIFIED PERSONNEL ONLY. NOTE: Modifying this charger for use other than that for which it was intended, repairs by persons not qualified, or not using original equipment replacement parts will void the manufacturer’s warranty and liability.

BATTERY CHARGER SERVICE MANUAL

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 3

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GENERAL INFORMATION

The Nilfisk-Advance Battery Chargers are designed to recharge deep-cycling lead acid batteries. A ferroresonant transformer is used to provide a highly reliable, line compensating unit with a minimum of moving parts, designed for long trouble-free service. The chargers are constructed so that all parts can be tested and replaced with basic hand tools. In addition, an analog multimeter of 10,000 ohms per volt sensitivity or better is required.

The Nilfisk-Advance battery charger is comprised of two basic sections; the transformer/rectifier or power section, and the on/off control section.

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TRANSFORMER / RECTIFIER OR POWER SECTION

The power or charging section consists of a transformer with its specified part number and rating capacitor and rectifying diodes attached to a heat sink. The ammeter displays charging current and the fusing provides electrical protection.

The transformer consists of primary coil or coils separated from the capacitor and secondary coils by a stack of transformer grade steel pieces called a shunt pack. The transformer coils are wound with high temperature double insulated magnet wire. The leads are covered with tan or black sleeving and all termination connectors are crimped and soldered. The transformer must be properly connected in accordance with the correct wiring diagram for each specific part number charger.

The capacitor functions in combination with the specific transformer to provide the correct charger output with variation in AC line voltage. The correct part number and rating capacitor as listed on the parts list must be used with the correct part number transformer and charger.

CAUTION!

Use only the correct part number and rating capacitor. Use of a different capacitor may result in improper charging, capacitor failure, transformer burnout and / or battery damage.

The rectifier diodes are attached to a heatsink plate or bracket that is fastened to, but electrically isolated from, the charger chassis. Connection points are provided on the heatsink assembly with diodes. One connection point is to the heatsink plate itself or a tab attached to it, the remaining connections are to individual diode tabs or leads. More than one lead can be attached to each connection point and the heatsink assembly with diodes must be the right part number and connected in accordance with the correct wiring diagram for the specific part number charger.

The ammeter needle deflects in response to current flow indicating charge current. Connections to the ammeter terminals are either push on or with jam nuts. When tightening the jam nuts, insure the threaded stud does not turn, or damage to the ammeter can occur. Use only the correct ammeter as specified in the appropriate wiring diagram and parts list.

BATTERY CHARGER SERVICE MANUAL

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4 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

The fusing consists of a fuse link in series with each diode and provides overcurrent protection should one or both diodes fail in the shorted mode. When both fuses or fuse links blow, this is usually due to a reverse polarity connection to the batteries. Either two individual fuseholders with fuses or a single dual element fuse assembly provides this protection. The fuse assembly consists of a double ended fuse wire visable through a transparent bubble mounted on the front panel. Each half of the fuse wire serves as an individual fuse element. After correcting the reason for the fuse blowing, replace the fuse or fuse assembly only with the correct rating and part number in accordance with the correct wiring diagram and parts list for the specific part number charger.

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ON/OFF CONTROL SECTION

The ON/OFF control is provided by either a manually set hours of charge timer or the fully automatic battery condition sensing electronic timer kit.

The fully automatic timer section has three main components.

The, “Electronic Timer Kit”, consist of state of the art electronic circuitry on a printed circuit board contained in a protective sheet metal housing.

The “Control Cable Assembly”, has a polarized edge connector that mates with the circuit board pads on the rear of the electronic timer kit. The wires attached to the edge connector are the correct length, position and color to be connected in accordance with the proper wiring diagram for each specific part number charger.

The “On/Off Control Relay”, responds to signals from the electronic timer kit to either turn the AC power on or off to the transformer of the power section. The relay terminal nomenclature is printed on each relay case and should be connected according to the correct wiring diagram for each specific part number charger.

The manually set hours of charge timer is a simple electric clock motor operated on/off switch that turns off after the preset number of hours has elapsed. The push on connections are numbered and must be connected according to the correct wiring diagram for each specific part number charger.

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TRANSFORMER / RECTIFIER OR POWER SECTION (continued)

BATTERY CHARGER SERVICE MANUAL

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 5

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AUTOMATIC TIMER BATTERY CHARGER TROUBLESHOOTING

Proper functioning of the Automatic Battery Charger is indicated by the following sequence of events. Three to five seconds after the DC plug is connected to the charger receptacle the control relay “clicks” on, the transformer hums and the ammeter registers proper charge.

Proper diagnosing and repair requires identifying the malfunction from the following list, performing the indicated tests and repairing or replacing the malfunctioning items.

Malfunction Descrip1ion Test Procedures / Section Number

Relay does not “click” on when DC plug is Test for complete electrical connection to connected to the charger receptacle. batteries / 1.

Test for proper functioning of automatic timer components / 2.

Relay “clicks” on, but transformer does not Test AC power circuit / 3. hum.

Transformer hums but no ammeter indication. Test Charger DC Circuit / 7.

Test Fuses and Diodes / 6. Test Capacitor / 4. Test Transformer / 5.

Transformer hums but charger output is low. Test Fuses and Diodes / 6.

Test Transformer / 5.

Fuse blows as soon as DC plug is connected Test Charger DC Circuit / 7. to the charger receptacle. Test Fuses and Diodes / 6.

Ammeter remains pegged at maximum Check Battery System Voltage / 8. charge for more than 30 minutes.

Charger does not turn off. Test Automatic Timer Section for “Does Not

Turn Off” / 9.

WARNING!

Do not touch the battery terminals or contacts on the charging plug. An electrical shock could result.

BATTERY CHARGER SERVICE MANUAL

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6 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

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MANUAL TIMER BATTERY CHARGER TROUBLESHOOTING

Proper functioning of the charger is indicated by the following sequence of events. When the timer knob is turned to “ON”, the transformer hums and the ammeter registers proper charge.

Proper diagnosing and repair requires identifying the malfunction from the following list, performing the indicated tests and repairing or replacing the malfunctioning items.

Malfunction Description Test Procedures / Section Number

Transformer does not hum when the timer is Test AC Power Circuit / 3. turned to “ON”.

Transformer hums but no ammeter indication. Test for complete electrical connection

to battery system / 1. Test Charger DC Circuit / 7. Test Fuses and Diodes / 6. Test Capacitor / 4. Test Transformer / 5.

Transformer hums but charger output is low. Test Fuses and Diodes / 6.

Test Transformer / 5.

Fuse blows as soon as the charger is Test Fuses and Diodes / 6. connected to the batteries.

Ammeter remains pegged at maximum charge Check Battery System Voltage / 8. for more than 30 minutes.

Charger does not turn off. Replace Manual Timer.

WARNING!

Do not touch the battery terminals or contacts on the charging plug. An electrical shock could result.

BATTERY CHARGER SERVICE MANUAL

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 7

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1-CHECKING FOR COMPLETE ELECTRICAL CONNECTION TO THE BATTERIES

A Measure and record battery system voltage at the battery posts of the machine. Connect the positive (+)

voltmeter lead to the positive (+) battery system post and the negative (-) voltmeter lead to the negative (-) battery system post.

B Measure and record battery voltage at the charger receptacle. If no voltage is measured or the voltage

measured is lower than the voltage measured in step A, repair or replace connections to batteries in machine.

C See Figure 1. With both the AC cord and the charging plug disconnected, remove the cover from the

charger. Connect the positive voltmeter lead to the same point inside the charger where the white (+) DC cord lead connects. Connect the negative voltmeter lead to the same point inside the charger where the black (-) DC cord lead connects.

D Connect the DC Output cord to the charger receptacle and record the voltage measured. It should be the

same voltage as measured in step A.

E If no voltage is measured or the voltage measured is lower than the voltage measured in step A, repair or

replace the receptacle, charger plug and / or the cordset and re-test.

FIGURE 1. Testing for complete electrical connection to the battery system.

BATTERY CHARGER SERVICE MANUAL

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2-TEST FOR PROPER FUNCTIONING OF AUTOMATIC TIMER COMPONENTS

A With both the AC cord and the charging plug disconnected, remove the cover from the charger. Verify

that the charger is wired correctly according to appropriate wiring diagram for the specific part number charger.

B Remove the retaining screws and slide the

automatic timer kit out the front of the charger. Disconnect the edge connector from the automatic timer kit and insert the test kit (Fig. 2). Connect the DC plug to the charging receptacle and listen for the relay to “click” on. If the relay now “clicks” on, install a new automatic timer kit and re-test. If the relay does not “click” on, continue with the next test.

C Measure DC voltage across the pads on the

test kit that the red (Positive) and black (Negative) wires contact (Fig. 3). The meter should read the same battery voltage as recorded in 1-C. If no voltage is measured or the voltage measured is lower, repair or replace the control cable assembly and retest.

D Measure DC voltage across the pads on the

test kit that the black (Negative) and brown (Positive) wires contact. It should read the same battery voltage as recorded in 2-C. If no voltage is measured install a new control relay and retest.

FIGURE 2. Insert the test kit.

FIGURE 3. Measure battery system voltage at the test kit pads.

BATTERY CHARGER SERVICE MANUAL

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 9

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3-TEST AC POWER CIRCUIT

A Measure AC line voltage at the outlet to be sure the correct AC voltage for the specific part number

charger is present (115 VAC, or 230 VAC). If the correct AC power is present, disconnect the AC plug and the charging plug.

B Adjust the multimeter to the low resistance scale (R X 1) or use a low voltage continuity tester. Connect

the tester leads to the flat prongs on the AC plug.

• MANUAL TIMER CHARGER Turn the timer knob to “ON” and note the response. The circuit should be complete when the timer knob is turned to “ON”, (Fig. 4) and open when the timer knob is turned to “OFF”.

• AUTOMATIC TIMER CHARGER Connect the charging plug to the charging receptacle and listen for the control relay to “click” on, 2 to 5 seconds after connection.

• The circuit should be open before the relay “clicks” on and the circuit should be complete after the relay “clicks” on.

C If the circuit does not test as described, individually check the AC cord, manual timer contacts, control

relay contacts, primary transformer coil(s) and all connections.

DANGER!

HIGH VOLTAGE! With the charger on, the charger capacitor voltage is approximately 650 volts AC. Use extreme caution when working near the capacitor terminals.

FIGURE 4. Test AC circuit for continuity.

BATTERY CHARGER SERVICE MANUAL

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10 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

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4-TEST THE CAPACITOR

WARNING!

It is possible for the capacitor to not be fully discharged. To test for this, adjust your meter to the highest DC voltage scale and touch the test leads to the capacitor terminals and note the reading. If the meter needle deflects in the wrong direction reverse the test leads and repeat. If the capacitor was not fully discharged a voltmeter reading will indicate this. Continue holding the voltmeter leads on the capacitor terminals until the voltage reading drops to zero.

A Using the analog ohmmeter adjust the scale to R X 10,000 (1 Ok) Ohms. Loosen the capacitor clamp

and carefully remove both transformer leads from the capacitor terminals so the wires do not break. Touch the ohmmeter leads to the capacitor terminals and note the results. Reverse the test leads, repeat the test and compare to the following:

• GOOD CAPACITOR: When the ohmmeter leads are connected to the capacitor terminals the meter needle bumps up to mid scale and quickly coasts back to high resistance (∞).

• OPEN CAPACITOR: When the ohmmeter leads are connected to the capacitor the meter needle does not move and stays at high resistance (∞). A bulge in the top of the capacitor may be visable if the capacitor has failed “OPEN”.

• SHORTED CAPACITOR: When the ohmmeter leads are connected to the capacitor terminals, the meter needle jumps to full scale, zero ohms and remains there.

B If the capacitor is “Open” or “Shorted” it must be replaced.

CAUTION!

Use only the correct part number and rating capacitor as specified on the correct parts list for the specific part number charger. The use of a different part number or rating capacitor may result in improper charging, capacitor failure, transformer burnout, and / or battery damage.

BATTERY CHARGER SERVICE MANUAL

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 11

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5-TRANSFORMER TESTING

Testing the transformer consists of measuring the AC voltage across the transformer secondary leads that connect to the diodes. This voltage is measured first with the capacitor disconnected and compared to the voltage measured with a capacitor connected that has been tested and found good.

DANGER!

HIGH VOLTAGE! With the charger operating, the charger capacitor voltage is approximately 650 volts AC. Use extreme caution when working near capacitor terminals.

A Disconnect the transformer secondary coil leads #1 and #4 (TAN SLEEVING) from the diode terminals.

Loosen the capacitor strap and carefully disconnect the transformer capacitor coil leads from the capacitor terminals.

B Refer to the transformer test voltages diagram on the wiring diagram and parts list page for the specific

part number charger and adjust the voltmeter to an appropriate AC voltage range. Attach the meter test leads to the identified transformer coil leads.

C Checking to be sure for personal safety, and that no leads have been accidentally allowed to short, follow

the instructions below to energize the transformer primary.

• MANUAL TIMER CHARGER Turn the timer knob to “ON” and connect the power supply cord to an outlet while recording the voltage reading and unplug as soon as the reading is noted.

• AUTOMATIC TIMER CHARGER Connect the DC plug to the charger receptacle and listen for the relay to “click” on 2 to 5 seconds after the connection. Connect the AC power supply cord to an outlet while recording the voltage reading and unplug as soon as the reading is noted.

BATTERY CHARGER SERVICE MANUAL

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5-TRANSFORMER TESTING (continued)

• ALTERNATELY The relay contacts can be bypassed to enable transformer testing when the battery system is not present. Make up jumper leads (1 for 115 VAC, 2 for 230 VAC) with 3/16" (4.56 mm) wide flat blade push in connectors on both ends of a piece of 14 gauge flexible wire (Fig. 5). Carefully disconnect the AC cord lead and transformer primary lead (1 each 115 VAC, 2 each 230 VAC) from the relay terminals. Connect the jumper lead (1 for 115 VAC, 2 for 230 VAC) according to the transformer test diagram on the wiring diagram and parts list for the specific part number charger. Connect the AC power supply cord to an outlet while recording the voltage reading and unplug as soon as the reading is noted (Fig. 5).

D If the AC line fuse or circuit breaker blows, the transformer is shorted internally and must be replaced.

E Check the transformer secondary coil and capacitor coil voltage and compare to voltages on the trans-

former test diagram for the specific part number charger. If the voltages are substantially lower than those shown, the transformer is shorted internally and must be replaced.

F If the secondary coil voltage and capacitor coil voltage check good, re-test the secondary coil voltage with

the correct capacitor connected. If the secondary coil voltage is the same measured with the capacitor disconnected, the capacitor may be open, or the capacitor coil terminals may not be making proper contact.

FIGURE 5. Transformer test.

BATTERY CHARGER SERVICE MANUAL

Jumper Leads

Capacitor Leads Disconnected

Jumper Lead Connected

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 13

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6-TEST FUSES AND DIODES

Disconnect the AC power cord and the charging cord.

A Set the multimeter to the low resistance scale (R X 1 ) or use a low voltage continuity test light.

B Excessive heat due to a loose, corroded or distressed connection can cause one or both fuse assembly

links to melt and open. Fuseholders that are worn, corroded, bent or broken can result in an open circuit even when a good fuse is installed. Isolate the fuseholder assembly electrically and test for continuity with a good fuse installed.

C Electrically test and visually check the fuses and fuse assembly for continuity. A single blown fuse or

fuse link is normally caused by a short circuit failure of a single diode. When both fuses or fuse links are blown, this is usually due to a reverse polarity connection to the batteries. Test the diodes and correct the problem before replacing the fuse.

DANGER!

Replace the fuse or fuse assembly only with the correct fuse or fuse assembly. FIRE, PROPERTY DAMAGE AND PERSONAL INJURY CAN RESULT IF THE CHARGER IS USED WITH AN INCORRECT FUSE INSTALLED.

D To test the diodes, disconnect one transformer secondary coil lead (TAN SLEEVING) from the diode

terminal. Using the multimeter or a low voltage continuity tester, connect one lead to the diode heatsink plate or terminal, and the other lead to a diode terminal (Fig. 6). Note the response and then reverse the tester leads and check each diode again.

• GOOD DIODE: When the diode shows continuity in one direction but not the other.

• SHORTED DIODE: When the diode shows continuity in both directions.

• OPEN DIODE: When the diode does not show continuity in either direction.

E If the diode(s) is OPEN or SHORTED the

complete heatsink assembly with diode(s) must be replaced.

FIGURE 6. Test diodes.

BATTERY CHARGER SERVICE MANUAL

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7-CHARGER DC CIRCUIT TEST

Disconnect the AC power cord and the DC charger plug.

A Set multimeter to low resistance scale (R X 1) or use a low voltage continuity tester.

B Connect one lead of the ohmmeter or continuity tester to one of the DC charging plug contacts, and the

other to the remaining DC plug contacts and note the response. Reverse the test leads and note the response again. The circuit should be complete in one direction only (Fig. 7 & 8).

Note: When using a very sensitive ohmmeter, disconnect the control cable assembly edge connector from the electronic timer kit.

C If the circuit does not conduct in either direction and the fuses or fuse assembly test good, individually

check the continuity of the DC output cord, ammeter, diodes and all connections.

D If the circuit conducts in both directions, a “short” exists in the charger DC circuit. First check the DC

output cord for a “short” between the two wires. Second, check if one or more of the diodes has failed in the shorted mode.

FIGURE 7. Test charger DC circuit. The circuit conducts in one direction.

FIGURE 8. Test charger DC circuit. The circuit does not conduct in reverse direction.

BATTERY CHARGER SERVICE MANUAL

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 15

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8-AMMETER REMAINS AT MAXIMUM CHARGE FOR MORE THAN 30 MINUTES

This condition normally results if the charger is connected to a battery pack which is of lower system voltage than specified in the operaters manual and / or the charger case.

CAUTION!

Do not connect the charger to, or attempt to use the charger on battery packs of different DC voltage than specified on the front of the charger. Overheating and transformer burn-out will result.

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9-TEST AUTOMATIC TIMER SECTION FOR “DOES NOT TURN OFF”

A Disconnect the AC power supply cord and the DC charging plug. Remove the cover and verify that the

control cable assembly leads are securely connected in accordance with the correct wiring diagram for the specific part number charger.

B Using the test kit, check continuity of the green sense lead between the pad on the test kit in line with the

green wire and where the sense lead connects to the diode terminal. If the circuit is “open”, replace the control cable assembly.

C Connect the charger DC plug to the charging receptacle and then the AC power cord to turn the charger

on. Remove the automatic timer kit retaining screws and carefully slide the kit out the front of the charger. Disconnect the edge connector from the circuit board and note if the transformer hum ceases and the ammeter drops to zero. Does the charger now turn off?

• CHARGER DOES NOT TURN OFF: The control relay has frozen “ON”. Replace the relay with the correct part number as specified on the correct parts list for the specific part number charger.

• CHARGER TURNS OFF: The automatic timer kit is malfunctioning. Replace the automatic timer kit with the correct part number as specified on the correct parts list for the specific part number charger.

BATTERY CHARGER SERVICE MANUAL

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PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56206975 24 VOLT 10 AMP MANUAL

120 VAC 60 HZ

TRANSFORMER TEST DIAGRAM

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 36 to 44 VAC 54 to 66 VAC

Capacitor Approx.

Coil 395 VAC

A.C. Input - 120 VAC / 60HZ

BATTERY CHARGER PARTS LIST

Item Part No. Qty Description

* 56206904 1 Heatsink Assembly, With Diodes 1 56206905 1 Ammeter 2 56206906 1 Timer, 12 Hour

* 56206914 1 Knob, Timer 3 56206907 1 Capacitor, 2.0 MFD, 660 VAC

* 56206908 2 Bushing, 6N3-4, Insulator For Cordsets 5 56206910 1 Cordset, DC, 14/2, 108", Lester Plug 6 56206912 2 Fuse, 15 AMP, AGC-15

* 56206913 2 Fuseholder, HKP-HH, With 1/4 qd Tabs

* = Not Shown

TIMER

WHT

AC INLET PLUG

BLK

1

3

2

1

2

3

4

DIODE

FUSE

CAPACITOR

RED OR WHT

AMMETER

BLK

TO DC

PLUG

+

-

1

2

3

4

5

6

SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

TIMER

WHT

AC INLET PLUG

BLK

1

3

2

TAN

BLK

TAN

revised 8/00

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 17

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 36 to 44 VAC 54 to 66 VAC

Capacitor Approx.

Coil 370 VAC

A.C. Input - 120 VAC / 60HZ

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56206980 24 VOLT 10 AMP AUTOMATIC

120 VAC 60 HZ

TRANSFORMER TEST DIAGRAM

BATTERY CHARGER PARTS LIST

Item Part No. Qty Description

* 56206904 1 Heatsink Assembly, With Diodes 1 56206905 1 Ammeter 2 56206917 1 Electronic Timer Assembly 3 56206907 1 Capacitor, 2.0 MFD, 660 VAC

* 56206908 2 Bushing, 6N3-4, Insulator For Cordsets

* 56206982 1 AC Cord Strain Relief 5 56206910 1 Cordset, DC, 14/2, 108", Yellow Lester Plug

(used on 206980)

* 56324306 2 DC Charger Plug Contact

(used with SB 50 small red plug)

6 56206912 2 Fuse, 15 AMP, AGC-15

* 56206913 2 Fuseholder 7 56206919 1 Relay, 24VDC, SP, 15 AMP

* 56206921 1 Test Kit, E.T. Bypass

* = Not Shown

AC INLET PLUG

RED

TO DC

PLUG

+

-

4

ELECT.

TIMER

BLK

WHT

RELAY

BRN

GRN

BLK

RED

TRANSFORMER

TAN

BLK

TAN

DIODE

FUSE

CAPACITOR

AMMETER

BLK

WHT

BLK GRN

BRN

2

7

3

1

6

5

6 5 4 3 2 1

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

TAN

BLK

TAN

revised 8/00

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18 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 36 to 44 VAC 54 to 66 VAC

Capacitor Approx.

Coil 435 VAC

A.C. Input - 120 VAC / 60HZ

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56372945 24 VOLT 20 AMP MANUAL

120 VAC 60 HZ

TRANSFORMER TEST DIAGRAM

BATTERY CHARGER PARTS LIST

Item Part No. Qty Description

* 56373047 1 Heatsink Assembly, With Diodes 1 56373048 1 Ammeter 2 56206906 1 Timer, 12 Hour

* 56206914 1 Knob, Timer 3 56373049 1 Capacitor, 4.0 MFD, 660 VAC

* 56373050 2 Bushing, 7W-2, Insulator For Cordsets 4 56373051 1 Cordset, AC, 14/3, 78", Molded Plug 5 56373053 1 Cordset, DC, 12/2, 108", SB175 Red Plug 6 56373054 1 Fuse Assembly

* 56372045 1 Case Assembly

* 56373046 1 Transformer Assembly

* = Not Shown

SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

TIMER

WHT

AC INLET PLUG

BLK

1

3

2

TAN

BLK

TAN

TIMER

WHT

AC INLET PLUG

BLK

1

3

2

1

2

3 4

DIODE

FUSE ASSY

CAPACITOR

RED OR WHT

AMMETER

BLK

TO DC

PLUG

+

-

1

2

3

4

5

6

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 19

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 36 to 44 VAC 54 to 66 VAC

Capacitor Approx.

Coil 430 VAC

A.C. Input - 120 VAC / 60HZ

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56372947 24 VOLT 20 AMP AUTOMATIC

120 VAC 60 HZ

TRANSFORMER TEST DIAGRAM

BATTERY CHARGER PARTS LIST

Item Part No. Qty Description

1 56373056 1 Transformer Assembly

* 56373047 1 Heatsink Assembly, With Diodes 2 56373048 1 Ammeter 3 56373057 1 Electronic Timer Assembly 4 56373049 1 Capacitor, 4.0 MFD, 660 VAC

* 56373050 2 Bushing, 7W-2, Insulator For Cordsets 5 56373058 1 Cordset, AC, 14/3, 78", Molded Plug 6 56373053 1 Cordset, DC, 12/2, 108", SB175 Red Plug 7 56373054 1 Fuse Assembly 8 56206919 1 Relay, 24VDC, SP, 15 AMP

* 56373059 1 Control Cable Assembly

* 56206921 1 Test Kit, E.T. Bypass

* 56373055 1 Case Assembly

* = Not Shown

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

TAN

BLK

TAN

AC INLET PLUG

RED

TO DC

PLUG

+

-

5

ELECT.

TIMER

BLK

WHT

RELAY

BRN

GRN

BLK

RED

TRANSFORMER

TAN

BLK

TAN

DIODE

CAPACITOR

AMMETER

BLK

WHT

BLK GRN

BRN

3

8

4

2

7

6

FUSE ASSY

1

6 5 4 3 2 1

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

20 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56388109 24 VOLT 25 AMP AUTOMATIC

120 VAC 60 HZ

Item Part No. Qty Description

1 56388557 1 Capacitor 2 56206919 1 Relay, 24VDC, 15 AMP 4 56373054 1 Fuse Assembly 5 56373053 1 DC Cordset, SB-175 Red Plug

* 56373055 1 Control Cable * 56373050 2 Bushing, 7W-2 * 56373072 1 Heatsink Assembly, With Diodes

6 56373069 1 Ammeter

* 56206921 1 Test Kit, E.T. Bypass * 56373057 1 Electronic Timer Kit

* = Not Shown

TRANSFORMER TEST DIAGRAM

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 36 to 44 VAC 54 to 66 VAC

A.C. Input - 120 VAC / 60HZ

BATTERY CHARGER PARTS LIST

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

TAN

BLK

TAN

AC INLET PLUG

TO DC

PLUG

+

-

ELECT. TIMER

BLK

WHT

RELAY

BRN

GRN

BLK RED

TRANSFORMER

TAN

BLK

TAN

DIODES

CAPACITOR

AMMETER

BLK

WHT

3

2

1

6

4

5

FUSE ASSY

DIODES

ORN

revised 8/00

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 21

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 55 to 65 VAC 83 to 97 VAC

Capacitor Approx.

Coil 460 VAC

A.C. Input - 120 VAC / 60HZ

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56372955 36 VOLT 20 AMP MANUAL

120 VAC 60 HZ

TRANSFORMER TEST DIAGRAM

BATTERY CHARGER PARTS LIST

Item Part No. Qty Description

* 56373047 1 Heatsink Assembly, With Diodes 1 56373048 1 Ammeter 2 56206906 1 Timer, 12 Hour

* 56206914 1 Knob, Timer 3 56373049 1 Capacitor, 4.0 MFD, 660 VAC

* 56373050 2 Bushing, 7W-2, Insulator For Cordsets 4 56373051 1 Cordset, AC, 14/3, 78", Molded Plug 5 56373063 1 Cordset, DC, 12/2, 108", SB175 Red Plug 6 56373054 1 Fuse Assembly

* 56373061 1 Case Assembly

* 56373062 1 Transformer Assembly

* = Not Shown

SECONDARY COIL

1

2

3

4

CAPACITOR COIL

SECONDARY TEST POINTS

CAPACITOR

TEST POINTS

TIMER

WHT

AC INLET PLUG

BLK

1

3

2

TAN

BLK

TAN

TIMER

WHT

AC INLET PLUG

BLK

1

3

2

1

2

3

4

DIODE

FUSE ASSY

CAPACITOR

RED OR WHT

AMMETER

BLK

TO DC

PLUG

+

-

1

2

3

4

5

6

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22 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 55 to 65 VAC 83 to 97 VAC

Capacitor Approx.

Coil 445 VAC

A.C. Input - 120 VAC / 60HZ

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56395101 (replaces part numbers 56372947 & 56395347)

36 VOLT, 20 AMP, AUTOMATIC 120 VAC 60 HZ

TRANSFORMER TEST DIAGRAM

Item Part No. Qty Description

* 56373064 1 Case Assembly

1 56373065 1 Transformer Assembly

* 56373047 1 Heatsink Assembly, With Diodes 2 56373048 1 Ammeter 3 56373066 1 Electronic Timer Assembly 4 56373049 1 Capacitor, 4.0 MFD, 660 VAC

* 56373050 2 Bushing, 7W-2, Insulator For Cordsets 5 56373058 1 Cordset, AC, 14/3, 78", Molded Plug 6 56373063 1 Cordset, DC, 12/2, 108", SB175 Red Plug 7 56373054 1 Fuse Assembly 8 56206919 1 Relay, 24VDC, SP, 15 AMP

* 56206921 1 Test Kit, E.T. Bypass

* = Not Shown

BATTERY CHARGER PARTS LIST

RELAY

JUMPER

AC

INLET

PLUG

PRIMARY COIL SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

TAN

BLK

TAN

AC INLET PLUG

RED

TO DC

PLUG

+

-

5

ELECT.

TIMER

BLK

WHT

RELAY

BRN

GRN

BLK

RED

TRANSFORMER

TAN

BLK

TAN

DIODE

CAPACITOR

AMMETER

BLK

WHT

BLK

GRN

BRN

3

8

4

2

7

6

FUSE ASSY

1

6 5 4 3 2 1

revised 8/00

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 23

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56388502 36 VOLT 25 AMP AUTOMATIC

120 VAC 60 HZ

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 55 to 65 VAC 83 to 97 VAC

Capacitor Approx.

Coil 420 VAC

A.C. Input - 120 VAC / 60HZ

Item Part No. Qty Description

* 56388555 1 Heatsink Assembly, With Diodes 1 56388556 1 Ammeter 2 56373066 1 Electronic Timer Assembly 3 56388557 1 Capacitor, 4.0 MFD, 660 VAC

* 56373050 2 Bushing, 7W-2, Insulator For Cordsets 4 56373058 1 Cordset, AC, 14/3, 78", Molded Plug 5 56373063 1 Cordset, DC, 12/2, 108", SB175 Plug 6 56373054 1 Fuse Assembly 7 56206919 1 Relay, 24VDC, SP, 15 AMP

* 56206921 1 Test Kit, E.T. Bypass

* = Not Shown

TRANSFORMER TEST DIAGRAM

BATTERY CHARGER PARTS LIST

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2

3

4

CAPACITOR COIL

SECONDARY TEST POINTS

CAPACITOR

TEST POINTS

TAN

BLK

TAN

AC INLET PLUG

RED

TO DC

PLUG

+

-

4

ELECT. TIMER

BLK

WHT

RELAY

BRN

GRN

BLK

RED

TRANSFORMER

TAN

BLK

TAN

DIODE

CAPACITOR

AMMETER

BLK

WHT

BLK

GRN

BRN

2

7

3

1

6

5

FUSE ASSY

6 5 4 3 2 1

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

24 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56388120 36 VOLT 35 AMP AUTOMATIC

120 VAC 60 HZ

TRANSFORMER TEST DIAGRAM

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 55 to 65 VAC 83 to 97 VAC

A.C. Input - 120 VAC / 60HZ

BATTERY CHARGER PARTS LIST

Item Part No. Qty Description

1 56388557 1 Capacitor 2 56206919 1 Relay, 24VDC, 15 AMP 3 56373066 1 Electronic Timer Kit 4 56373058 1 AC Cordset 14/3, 78", Molded Plug

* 56373050 2 Bushing, 7W-2

* 56373073 1 Heatsink Assembly, With Diodes 5 56373070 1 Ammeter 6 56373074 1 Cordset, DC 7 56373071 1 Fuse Assembly

* 56206921 1 Test Kit, E.T. Bypass

* = Not Shown

AC INLET PLUG

TO DC

PLUG

+

-

ELECT.

TIMER

BLK

WHT

RELAY

BRN

GRN

BLK

RED

TRANSFORMER

TAN

BLK

TAN

DIODES

CAPACITOR

AMMETER

BLK

WHT

3

2

1

5

7

6

FUSE ASSY

DIODES

ORN

4

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2

3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

TAN

BLK

TAN

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 25

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56409494 36 VOLT 45 AMP AUTOMATIC

221-250 VAC 50-60 HZ

Item Part No. Qty Description

1 56409699 1 Ammeter

* 56409700 2 Heatsink Assembly

2 56409701 1 Electronic Timer Assembly

* 56409702 3 Bushing, Insulator

* 56409703 1 Control Cable Assembly 3 56409704 1 Cordset, AC 4 56409706 1 Cordset, DC, SB-175 Plug

* 56409707 1 Fuseholder, 30 Amp, 600 Volt, 2 Pole 5 56409708 1 Fuse, DC, 125 Amp, JJN-125 6 56409709 2 Fuse, AC, 25 Amp, FLM-25 7 56409710 1 Shunt, Electronic 8 56409711 1 Terminal Strip, 2 Pole

* = Not Shown

BATTERY CHARGER PARTS LIST

BLACK GREEN

2

3

RELAY

JUMPER

AC

INLET

PLUG

PRIMARY COIL SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

4

5

RED OR

WHITE

JUMPER

TRANSFORMER TEST DIAGRAM

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 55 to 65 VAC 83 to 97 VAC

Capacitor Approx.

Coil 410-470 VAC

A.C. Input - 230 VAC / 50HZ

200-220/221-250 VAC INPUT

BLACK

GREEN

WHITE

AC

FUSE

BROWN

TRANSFORMER

AC

FUSE

200-221

SETTING

221-250

SETTING

200-221

SETTING

SHOWN

5

6

7

8

9

10

WHITE

11

12

WHITE

TAN

13

14

1

2

3

4

TAN

BLACK

TAN

SCR

BLACK

WHITE

YELLOW

SHUNT

RED

ORANGE

WHITE BLACK WHITE

YELLOW

BROWN BROWN

ELECTRIC

TIMER

1

2

3

4

5

6

7

9

DC

FUSE

TO DC

PLUG

RED

AMMETER

+

BLACK BLACK

-

1

2

3

4

5

6

7

8

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26 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

BATTERY CHARGER PARTS LIST

WHITE

GREEN

1

3

2

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2 3

4

CAPACITOR COIL

SECONDARY TEST POINTS

CAPACITOR

TEST POINTS

BLACK

TRANSFORMER TEST DIAGRAM

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 17 to 23 VAC 27 to 33 VAC

Capacitor Approx.

Coil 410-470 VAC

A.C. Input - 120 VAC / 60HZ

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56411058 12 VOLT 10 AMP AUTOMATIC

120 VAC 60 HZ

+

-

BLACK

RED OR

WHITE

TO DC PLUG

AMMETER

BLACK

RED

GREEN

DIODE

TRANSFORMER

TAN

1

2

FUSES

BLACK

DIODE

TAN

3

4

CAPACITOR

2

3

1

ELECTRONIC TIMER

LOW BATTERY

VOLTAGE START

SWITCH

BLACK

GREEN

WHITE

115 VAC

INPUT

PLUG

1

2

3

4

5

6

7

Item Part No. Qty Description

* 56411083 1 Heatsink Assembly, W/Diodes 1 56411084 1 Ammeter 2 56411085 1 Electronic Timer Assembly 3 56411086 1 Capacitor, 2.0 MFD, 660 VAC

* 56411087 2 Bushing, 6N3-4, Insulator for Cordset 4 56411088 1 Cordset, AC 5 56411089 1 Cordset, DC W/SB-50 Amp Grey Plug

* 56411090 2 Fuseholder Assembly 6 56478271 2 Fuse, 15 Amps 7 56411091 1 Switch, Rocker

* 56411082 1 Transformer Assembly

* = Not Shown

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 27

WHITE

GREEN

1

3

2

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2

3

4

CAPACITOR COIL

SECONDARY

TEST POINTS

CAPACITOR

TEST POINTS

BLACK

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56411643 12 VOLT 20 AMP AUTOMATIC

120 VAC 60 HZ

Item Part No. Qty Description

*

56411647 1 Heatsink Assembly, W/Diodes 1 56411648 1 Ammeter 2 56411649 1 Electronic Timer Assembly 3 56411650 1 Capacitor, 3.0 MFD, 660 VAC

* 56411651 2 Bushing, SR-5KN-4, Insulator for DC Cordset 4 56411653 1 Cordset, AC 5 56411654 1 Cordset, DC W/SB-50 Amp Red Plug 6 56478655 1 Switch Assembly 7 56411657 1 Fuse, 5 Amps, MDA-5 9 56411659 1 Relay, 12V / 10A, SPST

* 56411087 1 Bushing 6N3-4 Insulator Cordset

* 56411645 1 Case Assembly

* 56411679 1 Control Cable Assembly

* 56411646 1 Trasformer Assembly

* = Not Shown

BATTERY CHARGER PARTS LIST

TRANSFORMER TEST DIAGRAM

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 17 to 23 VAC 27 to 33 VAC

Capacitor Approx.

Coil 410-470 VAC

A.C. Input - 120 VAC / 60HZ

+

-

BLACK

WHITE

TO DC

PLUG

AMMETER

BLACK

RED

GREEN

DIODE

TRANSFORMER

TAN

1

2

CIRCUIT

BREAKERS

BLACK

DIODE

TAN

3

4

CAPACITOR

ELECTRONIC TIMER

LOW BATTERY

VOLTAGE START

SWITCH

BLACK

GREEN

WHITE

115 VAC

INPUT

PLUG

RELAY

ORANGE

BROWN

WHITE

BLACK

1

2

3

4

5

6

7

8

9

10

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

28 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

BLACK GREEN

2

3

RELAY

JUMPER

AC INLET PLUG

PRIMARY COIL SECONDARY COIL

1

2

3

4

CAPACITOR COIL

SECONDARY TEST POINTS

CAPACITOR

TEST POINTS

4

5

RED OR

WHITE

JUMPER

BATTERY CHARGER PARTS LIST

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56409788 36 VOLT 38 AMP AUTOMATIC

221-250 VAC 50-60 HZ

Item Part No. Qty Description

1 56409795 1 Ammeter 2 56409700 2 Heatsink Assembly 3 56409796 1 Electronic Timer Assembly 4 56409702 3 Bushing, Insulator

* 56409797 1 Control Cable Assembly 5 56409704 1 Cordset, AC 6 56409706 1 Cordset, DC, SB-175 Plug

* 56409707 1 Fuseholder, 30 Amp, 600 Volt, 2 Pole 7 56409708 1 Fuse, DC, 125 Amp, JJN-125 8 56409709 2 Fuse, AC, 25 Amp, FLM-25

* 56409798 2 Scr Assy, 55A/400V, with wires

* 56409799 1 Electronic Control/Timer Assy 36V, 38/14 Amps 9 56409800 1 Input Voltage Adjust Terminal Block, 30A/300V, 2 Pole

* 56409793 1 Case Assembly

* 56409794 1 Transformer Assembly

TRANSFORMER TEST DIAGRAM

Test Capacitor Capacitor

Position Disconnected Connected

Secondary Approx. Approx.

Coils 55 to 65 VAC 83 to 97 VAC

Capacitor Approx.

Coil 410-470 VAC

A.C. Input - 230 VAC / 50HZ

1

2

3

4

5

6

7

9

ELECTRONIC TIMER

14

11

12

13

RED

ORANGE

WHITE

BLACK

WHITE

YELLOW

BROWN BROWN

SHUNT

OUTPUT

BUSHINGS

+

-

BLACK (+)

BROWN

BLACK

TAN

HEATSINKS

BROWN

BLACK

TAN

SCR

ASS'Y

BLACK

DC

FUSE

BLACK

AMMETER

BLACK (-)

TO DC

PLUG

3

4

2

1

PRI

SEC SEC

TRANSFORMER

5 6

7

8 9

10

1112 13 14

8

5

9

7

10

6

AC

FUSE

AC

FUSEHOLDER

200219

220240

INPUT

VOLTAGE

ADJUST

(220-240 SETTING SHOWN)

BLACK

WHITE

OR RED

GREEN

INPUT

BUSHING

INPUT

CORDSET

CASE GROUND

INPUT VOLTAGE 200-219 OR 220-240 VAC

1

2

3

4

5

4

6

7

8

9

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 29

AC

INPUT

BLACK

GREEN

WHITE

BLACK

DC

OUTPUT

TRANSFORMER

+

-

CONTROL

BOARD

POWER

SWITCH

THERMAL

PROTECTOR

FUSE

BATTERY CHARGER PARTS LIST

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56205983 (replaces part number 56206981)

24 VOLT 12 AMP AUTOMATIC 120 VAC 60 HZ

Part No. Qty Description

56411087 1 Bushing 6N3-4 Insulator Cordset 56205148 2 Case Assembly 56205153 1 Control Board Assembly 56205150 3 Cordset AC 18/3 102" w/Plug 56205152 1 Cordset DC 14/2 108" w/SB50 Red Plug 56205154 1 Power Switch 56205149 1 Transformer

revised 8/00

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30 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

AMMETER

GREEN

WHITE

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

TO

BATTERIES

CASE GROUND

AC

CORDSET

SECONDARY

PRIMARY

RED

BLACK

TAN

BLACK

ELECTRONIC

TIMER KIT

HEATSINK ASSEMBLIES

WITH DIODES

1

2

3

RELAY

GROUNDED

AC INPUT

DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK

DC CORDSET

1

2

3

4

BATTERY CHARGER PARTS LIST

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56412272 24 VOLT, 36 to 8 AMP AUTOMATIC

120 VAC 60 HZ

Part No. Qty Description

56373070 1 Ammeter 50 Amp w/Mounting Studs 56373073 2 Heatsink Assy w/2 Diodes in Parallel 56388557 1 Capacitor 6MFD 660 VAC 56409702 3 Bushing, Insulator 56412451 1 Case Assembly 56412457 1 Cordset, AC 14/3 86" w/125V/15a Plug 56412456 1 Cordset Bushing 8P-2 56412458 1 Cordset DC 10/2 108" w/SB175 Red Plug 56373071 1 Fuse Assembly 56412454 2 Timer Kit 24 VDC 120 VAC 56412455 2 Timer Kit Relay 24 VDC 120 VAC 56412452 1 Transformer Assembly

revised 8/00

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 31

revised 8/00

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56206973 24 VOLT 10 AMP AUTOMATIC

230 VAC 50 HZ

BATTERY CHARGER PARTS LIST

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

HEATSINK ASS'Y W/DIODES

ELECTRONIC TIMER ASS‘Y

GREEN OR GREEN W/YELLOW

RED OR WHITE OR BLUE

BLACK OR BROWN

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

1

2

3

GREEN

TO

BATTERIES

CASE GROUND

4

OUTPUT CORDSET

INPUT

CORDSET

SECONDARY

PRIMARY

RED

BLACK

CONTROL

CABLE ASS‘Y

1

5 4 3 2

TAN

AC

INPUT

BUSHING

OUTPUT

BUSHING

OUTPUT POLARITY: NEGATIVE: -, OR BLACK POSITIVE: +, RED OR WHITE

AMMETER

RED

BROWN

RELAY

'

)*$"

%

Part No. Qty Description

56373066 1 Timer Kit 56373070 1 Ammeter 56373073 1 Heatsink Assembly w/ Diodes 56373071 1 Fuse Assembly 56388557 1 Capacitor, 6 MFD, 660 VAC 56373074 1 Cordset, DC, 10/2, 108", SB175 Plug

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32 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

revised 8/00

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56372203 24 VOLT 20 AMP AUTOMATIC

230 VAC 50 HZ

Part No. Qty Description

56388557 1 Capacitor, 6 MFD, 660 VAC/70C, 600 VAC/90C 56373047 1 Heatsink Assembly, w/ Diodes 56373054 1 Fuse Assembly 56409702 1 Insulator Bushing, for 12/2 DC Cordset

BATTERY CHARGER PARTS LIST

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

HEATSINK ASS'Y W/DIODES

ELECTRONIC TIMER ASS’Y

GREEN OR GREEN W/YELLOW

RED OR WHITE OR BLUE

BLACK OR BROWN

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

1

2

3

GREEN

TO

BATTERIES

CASE GROUND

4

OUTPUT

CORDSET

INPUT

CORDSET

SECONDARY

PRIMARY

RED

BLACK

CONTROL

CABLE ASS‘Y

1

5 4 3 2

TAN

AC

INPUT

BUSHING

OUTPUT

BUSHING

OUTPUT POLARITY: NEGATIVE: -, OR BLACK POSITIVE: +, RED OR WHITE

AMMETER

RED

BROWN

RELAY

9

AB64

7

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 33

revised 8/00

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56372190 36 VOLT 20 AMP AUTOMATIC

230 VAC 50 HZ

BATTERY CHARGER PARTS LIST

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

HEATSINK ASS'Y W/DIODES

ELECTRONIC

TIMER ASS’Y

GREEN OR GREEN W/YELLOW

RED OR WHITE OR BLUE

BLACK OR BROWN

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

1

2

3

GREEN

TO

BATTERIES

CASE GROUND

4

OUTPUT

CORDSET

INPUT

CORDSET

SECONDARY

PRIMARY

RED

BLACK

CONTROL

CABLE ASS‘Y

1

5 4 3 2

TAN

AC

INPUT

BUSHING

OUTPUT

BUSHING

OUTPUT POLARITY: NEGATIVE: -, OR BLACK POSITIVE: +, RED OR WHITE

AMMETER

RED

BROWN

RELAY

9

AB64

7

Part No. Qty Description

56373066 1 Timer Kit 56373070 1 Ammeter 56373073 1 Heatsink Assembly w/ Diodes 56373071 1 Fuse Assembly 56388557 1 Capacitor, 6 MFD, 660 VAC 56373074 1 Cordset, DC, 10/2, 108", SB175 Plug

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34 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

revised 8/00

PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56388119 36 VOLT 36 AMP AUTOMATIC

230 VAC 50 HZ

Part No. Qty Description

56373066 1 Timer Kit 56373070 1 Ammeter 56373073 1 Heatsink Assembly w/ Diodes 56373071 1 Fuse Assembly 56388557 1 Capacitor, 6 MFD, 660 VAC 56373074 1 Cordset, DC, 10/2, 108", SB175 Plug

BATTERY CHARGER PARTS LIST

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

HEATSINK ASS'Y W/DIODES

ELECTRONIC

TIMER ASS’Y

GREEN OR GREEN W/YELLOW

RED OR WHITE OR BLUE

BLACK OR BROWN

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

1

2

3

GREEN

TO

BATTERIES

CASE GROUND

4

OUTPUT

CORDSET

INPUT

CORDSET

SECONDARY

PRIMARY

RED

BLACK

CONTROL

CABLE ASS‘Y

1

5 4 3 2

TAN

AC

INPUT

BUSHING

OUTPUT

BUSHING

OUTPUT POLARITY: NEGATIVE: -, OR BLACK POSITIVE: +, RED OR WHITE

AMMETER

RED

BROWN

RELAY

9

AB64

7

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 35

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56031407 12 VOLT 38 AMP AUTOMATIC

120 VAC 60 HZ

Part No. Qty Description

56388557 1 Capacitor, 6 MFD, 660 VAC 56373073 2 Heatsink Assembly w/ 2 Diodes in Parallel 56373071 1 Fuse Assembly 56373070 1 Ammeter, 50 Amp, w/ Corner Mounting Studs 56409702 1 Cordset Bushing, 7W-2, for Input Cordset 56412456 1 Cordset Bushing, 8P-2, for Output Cordset 56412457 1 AC Cordset, 14/3, 86", w/ 125V/15A Plug

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

AMMETER

GREEN

WHITE

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

TO

BATTERIES

CASE GROUND

AC

CORDSET

SECONDARY

PRIMARY

RED

BLACK

TAN

BLACK

ELECTRONIC

TIMER KIT

HEATSINK ASSEMBLIES

WITH DIODES

1

2

3

RELAY

GROUNDED

AC INPUT

DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK

DC CORDSET

1

2

3

4

revised 8/00

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36 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56632342 24 VOLT, 25 to 8 AMP AUTOMATIC

115 VAC 60 HZ

Part No. Qty Description

56373047 1 Heatsink Assembly, w/Doiodes 56373054 1 Fuse Assembly 56412454 1 Relay, Timer Kit, 24 VDC 56409702 1 Bushing, 7W-2, Insulator for Cordsets 56373063 1 Cordset, DC, w/175 Amp Plug, Gray, 101" 56373053 1 Cordset, DC, w/175 Amp Plug, Red, 101"

1

2

3

4

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

AMMETER

GREEN

WHITE

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

GREEN*

TO

BATTERIES

CASE GROUND

DC CORDSET

AC

CORDSET

SECONDARY

PRIMARY

RED

BLACK

TAN

BLACK

ELECTRONIC

TIMER KIT

HEATSINK ASSEMBLY

WITH DIODES

1

2

3

RELAY

GROUNDED

AC INPUT

*GREEN WIRE NOT USED ON SOME MODELS.

revised 8/00

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 37

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56638431 24 VOLT, 18 to 4 AMP AUTOMATIC

120 VAC 60 HZ

Part No. Qty Description

56373054 1 Fuse Assembly 56373047 1 Heatsink Assembly w/Diodes 56409702 1 Bushing, 7W-2, Insulator for DC Cord 56206919 1 Relay, 24 VDC, SPST, 15 Amp 56373049 1 Capacitor, 4.0 MFD, 660 VAC

CAPACITOR

ELECTRONIC

TIMER ASSEMBLY

CONTROL

CABLE ASSEMBLY

TAN

BLACK

RED

GREEN

TAN

DIODE HEATSINK ASSEMBLY

DC CORDSET

OUTPUT

BUSHING

TO

BATTERIES

BLACK (-)

WHITE OR RED (+)

BLACK

AMMETER

FUSE

ASSEMBLY

TAN

WHITE

GREEN

BLACK

BROWN

ORANGE

CASE GROUND

GROUNDED

AC INPUT

AC

CORDSET

INPUT

BUSHING

RELAY

PRIMARY

SECONDARY

TRANSFORMER

1

2

4

3

+

-

5

4 3 2 1

revised 8/00

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38 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56638436 24 VOLT, 12 to 3 AMP AUTOMATIC

120 VAC 60 HZ

Part No. Qty Description

56205149 1 Transformer 56205154 1 Power Switch 56411087 2 Bushing, Strain Relief, For Cords 56205150 1 Cordset, AC, 18/3, 102", w/ Molded Plug 56205152 1 Cordset, DC, 14/2, 108", w/ SB50 Red Plug

AC

INPUT

BLACK

GREEN

WHITE

BLACK

DC

OUTPUT

TRANSFORMER

+

-

CONTROL

BOARD

POWER SWITCH

THERMAL

PROTECTOR

FUSE

revised 8/00

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 39

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56638439 24 VOLT, 36 to 8 AMP AUTOMATIC

120 VAC 60 HZ

Part No. Qty Description

56412452 1 Transformer Assembly 56388557 1 Capacitor, 6 MFD, 660 VAC 56373073 2 Heatsink Assembly w/ 2 Diodes in Parallel 56373071 1 Fuse Assembly 56373070 1 Ammeter, 50 Amp, w/ Corner Mounting Studs 56412454 1 Timer Kit, 24 VDC, 120 VAC 56412455 1 Timer Kit, Relay 24 VDC, SPSTNO, 120 VAC 56409702 1 Cordset Bushing, 7W-2, for Input Cordset 56412456 1 Cordset Bushing, 8P-2, for Output Cordset 56412457 1 AC Cordset, 14/3, 86" w/ 125V/15A Plug 56412458 1 DC Cordset, 10/2, 108", w/ SB175 Red Plug 56373074 1 DC Cordset, 10/2, 108", w/SB175 Gray Plug

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

AMMETER

GREEN

WHITE

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

TO

BATTERIES

CASE GROUND

AC

CORDSET

SECONDARY

PRIMARY

RED

BLACK

TAN

BLACK

ELECTRONIC

TIMER KIT

HEATSINK ASSEMBLIES

WITH DIODES

1

2

3

RELAY

GROUNDED

AC INPUT

DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK

DC CORDSET

1

2

3

4

revised 8/00

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40 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56638440 24 VOLT, 20 to 8 AMP AUTOMATIC

100, 125 or 200-250 VAC / 50 or 60 HZ

Part No. Qty Description

56373069 1 Ammeter 56409702 1 Bushing, Insulator, 7W-2, for DC Cordset 56206913 2 Fuseholder

POWER

SWITCH

AC VOLTAGE *

SELECTOR

SWITCH

BLACK

AC

FUSE

1

2

BLACK

1b 1a

2b

R

2

1

BROWN

GRAY

AC

FUSE

WHITE WHITE

BLACK GREEN

WHITE

100-125 200-225

VAC

INPUT

* SHOWN IN

100-125 VOLT

POSITION

BLUE

NATURAL

BLUE

8

7

6

5

4

3

SCR

BLACK

9

10

BLACK BLACK

11

12

BLACK

SCR

BROWN

SHUNT

ELECTRONIC

TIMER

9 7 6 5 4 3 2

1

BROWN

YELLOW

BLUE

BLACK

BLUE

ORANGE

RED

40 AMP

CIRCUIT BREAKER

WHITE

AMMETER

BLACK

DC

OUTPUT

+

-

BROWN

YELLOW

TRANSFORMER

revised 8/00

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 41

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56632293 36 VOLT, 25 to 8 AMP AUTOMATIC

115 VAC 60 HZ

Part No. Qty Description

56373047 1 Heatsink Assembly, W/Diodes 56373054 1 Fuse Assembly 56373069 1 Ammeter, 0-30 Amp 56409702 1 Bushing, 7W-2, Insulator for DC Cord 56373051 1 Cordset, AC, 14/3, 80", Molded Plug 56373063 1 Cordset, DC, 12/2, 108", SB175Gray Plug

1

2

3

4

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

AMMETER

GREEN

WHITE

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

GREEN*

TO

BATTERIES

CASE GROUND

DC CORDSET

AC

CORDSET

SECONDARY

PRIMARY

RED

BLACK

TAN

BLACK

ELECTRONIC

TIMER KIT

HEATSINK ASSEMBLY

WITH DIODES

1

2

3

RELAY

GROUNDED

AC INPUT

*GREEN WIRE NOT USED ON SOME MODELS.

revised 8/00

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42 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56031403 36 VOLT, 21 to 6 AMP AUTOMATIC

120 VAC 60 HZ

Part No. Qty Description

56373054 1 Fuse Assembly 56373047 1 Heatsink Assembly w/Diodes 56373069 1 Ammeter, 30 Amp, Corner Mount 56409702 1 Bushing, 7W-2, Insulator for DC Cord 56411650 1 Capacitor, 3.0 MFD, 660 VAC

CAPACITOR

ELECTRONIC

TIMER ASSEMBLY

CONTROL

CABLE ASSEMBLY

TAN

BLACK

RED

GREEN

TAN

DIODE HEATSINK ASSEMBLY

DC CORDSET

OUTPUT

BUSHING

TO

BATTERIES

BLACK (-)

WHITE OR RED (+)

BLACK

AMMETER

FUSE

ASSEMBLY

TAN

WHITE

GREEN

BLACK

BROWN

ORANGE

CASE GROUND

GROUNDED

AC INPUT

AC

CORDSET

INPUT

BUSHING

RELAY

PRIMARY

SECONDARY

TRANSFORMER

1

2

4

3

+

-

5 4 3 2

1

revised 8/00

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FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 43

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56031405 36 VOLT, 20 to 8 AMP AUTOMATIC

115 or 230 VAC / 50 or 60 HZ

Part No. Qty Description

56373069 1 Ammeter 56409702 1 Bushing, Insulator, 7W-2, for DC Cordset 56206913 1 Fuseholder

POWER

SWITCH

AC VOLTAGE *

SELECTOR

SWITCH

BLACK

AC

FUSE

1

2

BLACK

1b 1a

2b

R

2

1

BROWN

GRAY

AC

FUSE

WHITE WHITE

BLACK GREEN

WHITE

100-125 200-225

VAC

INPUT

* SHOWN IN

100-125 VOLT

POSITION

BLUE

NATURAL

BLUE

8

7

6

5

4

3

SCR

BLACK

9

10

BLACK BLACK

11

12

BLACK

SCR

BROWN

SHUNT

ELECTRONIC

TIMER

9 7 6 5 4 3 2 1

BROWN

YELLOW

BLUE

BLACK

BLUE

ORANGE

RED

40 AMP

CIRCUIT BREAKER

WHITE

AMMETER

BLACK

DC

OUTPUT

+

-

BROWN

YELLOW

TRANSFORMER

revised 8/00

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44 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

PARTS LIST FOR LESTER BATTERY CHARGER

PART NUMBER 56031408 36 VOLT, 36 to 8 AMP AUTOMATIC

120 VAC 60 HZ

Part No. Qty Description

56388557 1 Capacitor, 6MFD, 660 VAC 56373073 2 Heatsink Assembly w/ 2 Diodes in Parallel 56373071 1 Fuse Assembly 56373070 1 Ammeter, 50 Amp, w/ Corner Mounting Studs 56409702 1 Cordset Bushing, 7W-2, for 14/3 Input Cordset 56412456 1 Cordset Bushing, 8P-2, for 10/2 Output Cordset 56373074 1 DC Cordset, 10/2, 108", w/ SB175 Gray Plug

CAPACITOR

TRANSFORMER

FUSE

ASSEMBLY

AMMETER

GREEN

WHITE

+

-

TAN

BLACK (-)

TAN

WHITE OR RED (+)

BLACK

TO

BATTERIES

CASE GROUND

AC

CORDSET

SECONDARY

PRIMARY

RED

BLACK

TAN

BLACK

ELECTRONIC

TIMER KIT

HEATSINK ASSEMBLIES

WITH DIODES

1

2

3

RELAY

GROUNDED

AC INPUT

DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK

DC CORDSET

1

2

3

4

revised 8/00

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

Nilfisk-Advance, Inc.

14600 21st Avenue North Plymouth, MN, 55447-3408 www.nilfisk-advance.com Phone: 800-989-2235 Fax: 800-989-6566

For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net

Nilfisk-Advance 56395101, 56372947, 56206981, 56388109, 56388120 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual