Westward 1JYT9A, 1JYU2A, 1JYU1A, 1JYU3A Operating Instructions

Page 1

Operating Instructions and Parts Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Description

Westward battery chargers are mobile oor units designed to deliver maximum starting power. They charge up to 60 amperes (maximum) on 6 or 12 volt batteries (1JYT9A max 40 amps).

Chargers are equipped with a timer control, charging voltage and rate selector, ammeter and automatic reset circuit breaker.

Figure 1

Specications 1JYT9A 1JYU1A 1JYU2A 1JYU3A

Power Supply Requirements

Primary AC input@ rated 12 V output

Max Continuos Charge Output

Start Output @7.2V

Medium charge output

Motorcycle or nishing charging

Average Charging Time

Primary AC input@start

120 VAC, 60 Hz

8.5 Amps @120V 60 Hz

40 Amps @6/12V

200 Amps @7.2V 130 Amps @6V

20 Amps @12V

2 Amps @12V

3/4 to 1/2 hr

29 Amps

120 VAC, 60 Hz

12.0 Amps @120V 60 Hz

60 Amps @6/12V

250 Amps @7.2V 185 Amps @6V

40 Amps @12V

2 Amps @12V

1/2 to 1 hr

43 Amps

Important Safety Instructions

READ THESE FIRST

1. SAVE THESE INSTRUCTIONS.

This manual contains important safety and operating instructions.

2. Do not expose charger to rain or snow.

3. Use of an attachment not recommended or sold by the manufacturer may result in a risk of re, electric shock, or injury to persons.

4. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting charger.

5. An extension cord should not be used unless absolutely necessary.

120 VAC, 60 Hz

12.0 Amps @120V 60 Hz

60 Amps @6/12V

250 Amps @7.2V 185 Amps @6V

0-60 Amps @6/12V

0-3 Amps @6/12V

1/2 to 1 hr

58 Amps

120 VAC, 60 Hz

12.0 Amps @120V 60 Hz

60 Amps @6/12V

225 Amps @7.2V 160 Amps @6V

40 Amps @12V

Not Applicable

1/2 to 1 hr

35 Amps

E N G

S H

30 Amps @24V

Form 5S4079

Printed in Taiwan 05/10 JL06

Page 2

Westward Operating Instructions and Parts Manual

Westward

Battery Chargers

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Important Safety Instructions

E N G

S H

(Continued)

Use of improper extension cord could result in a risk of re and electric shock.

If extension cord must be used, make sure that the extension cord plug pins are the same number, size, and shape as the charger plug, that the extension cord is properly wired and in good electrical condition, and that the wire size is large enough for the length of cord as specied in the following chart:

Length of AWG size cord in feet of cord

25 16

50 12

100 10

150 8

6. Do not operate charger with damaged cord or plug. Replace the cord or plug immediately.

7. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualied service person.

8. Do not disassemble charger; take it to a qualied service person when service or repair is required. Incorrect reassembly may result in a risk of electric shock or re.

9. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. Turning o controls will not reduce this risk.

vicinity of a lead acid battery is dangerous. Batteries generate explosive gases during normal battery operation. For this reason, it is of utmost importance that each time before using your charger, you read this and follow the instructions exactly.

To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend to use in vicinity of battery. Review cautionary markings on these products and in engine compartment.

PERSONAL PRECAUTIONS

1. Someone should be within range of your voice or close enough to come to your aid when you work near a lead acid battery.

2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.

4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately ush eye with running cold water for at least 10 minutes and get medical attention immediately.

5. NEVER smoke or allow a spark or ame in vicinity of battery or engine.

6. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion.

RISK OF EXPLOSIVE GASES. Working in

7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a leadacid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.

8. Use charger for charging LEAD-ACID battery only. It is not intended to supply power to a low voltage electrical system other than in a starter-motor application. Do not use battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property.

9. NEVER charge a frozen battery.

PREPARING TO CHARGE BATTERY

1. If necessary to remove battery from vehicle to charge, always remove grounded terminal from battery rst. Make sure all accessories in the vehicle are o, so as not to cause an arc.

2. Be sure area around battery is well ventilated while battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other nonmetallic material as a fan.

3. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.

4. Add distilled water in each cell until battery acid reaches level specied by battery manufacturer. This helps purge excessive gas from cells. Do not overll. For a battery without cell caps, carefully follow manufacturer’s recharging instructions.

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Westward Operating Instructions and Parts Manual

Models 1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Important Safety Instructions (Continued)

5. Study all battery manufacturer’s specic precautions such as removing or not removing cell caps while charging and recommended rates of charge.

6. Determine voltage of battery by referring to car owner’s manual and make sure that output voltage selector switch is set at correct voltage.

LOCATING THE CHARGER

1. Locate charger as far away from battery as DC cables permit.

2. Never place charger directly above battery being charged; gases from battery will corrode and damage charger.

3. Never allow battery acid to drip on charger when reading gravity or lling battery.

4. Do not operate charger in a closed area or restrict ventilation in any way.

5. Do not set a battery on top of charger.

GROUNDING AND AC POWER CORD CONNECTIONS

Charger should be grounded to reduce risk of electric shock. Charger is equipped with an electric cord having an equipment-grounding conductor and grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Never alter AC cord

or plug provided. If it will not t outlet, have proper outlet installed by a qualied electrician. Improper connection can result in risk of an electric shock.

Connect and

disconnect DC output clips only after setting any switches with an OFF position to OFF and removing AC cord from electric outlet. Never allow clips to touch each other.

BATTERY CHARGER CONNECTION PRECAUTIONS

1. When hooking up charger, attach

one clip to battery and the other to a point away from battery (see “Charging a Battery Installed in Vehicle”, and “Charging a Battery Outside the Vehicle”). Do not hook up charger until reading the entire manual. To reduce explosion risk, never connect both clips directly to the battery. When making each connection, twist or rock clip back and forth several times to make a good connection and to reduce the risk of a clip slipping o and creating a spark. Do not twist or rock clip on the battery after the second clip connection is made.

CHARGING A BATTERY INSTALLED IN VEHICLE

A marine (boat)

battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use.

A spark near

battery may cause battery explosion. To reduce risk of a spark near battery:

1. Position AC and DC cords to reduce

risk of damage by hood, door, or moving engine part.

2. Stay clear of fan blades, belts, pulleys,

and other parts that can cause injury to persons.

3. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger diameter than NEGATIVE (NEG, N, -) post.

4. Determine which post of battery is grounded (connected) to the chassis. If the negative post is grounded to the chassis (as in most vehicles), see Figure 2 and instruction “5a”. If the positive post is grounded to the chassis, see Figure 3 and instruction “5b”.

Negative to Chassis Ground

Positive

Figure 2

Positive to Chassis Ground

Figure 3

E N G

S H

Negative

Page 4

Westward Operating Instructions and Parts Manual

Westward

Battery Chargers

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Important Safety Instructions

E N G

S H

(Continued)

5. a. For NEGATIVE-GROUNDED vehicle, connect POSITIVE (red) clip from the battery charger to the POSITIVE (POS, P, +) ungrounded post of the battery.

b. For POSITIVE-GROUNDED vehicle, connect the NEGATIVE (black) clip from the battery charger to the NEGATIVE (NEG, N, -) ungrounded post of the battery.

6. Connect the remaining battery charger clip to the vehicle chassis or engine block, as far away from the battery as possible. Do not connect the clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy-gauge metal part of the frame or engine block.

7. When disconnecting charger, turn all switches with an OFF position to OFF, disconnect AC cord, remove clip from vehicle chassis, and then remove clip from battery terminal.

CHARGING A BATTERY OUTSIDE THE VEHICLE

A spark near the

battery may cause battery explosion. To reduce risk of a spark near battery:

1. Check polarity of battery posts.

POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, -) post.

2. Attach a cable (not provided) to the

NEGATIVE (NEG, N, -) battery post.

This cable must be a minimum of 24” long, and of a wire gauge that is no lighter than the wire gauge of the charger’s output cables (battery cables and booster cables work well) (See Figure 4).

Cable from Charger

Figure 4

3. Connect POSITIVE (red) charger clip to POSITIVE (POS, P, +) post of battery.

4. Position yourself and the free end of the cable (installed in Step #2) as FAR away from the battery as possible. FACING AWAY FROM THE BATTERY, connect the NEGATIVE (black) charger clip to the free end of the cable.

5. When disconnecting charger, always do so in reverse sequence of connecting procedure and break rst connection while as far away from battery as practical.

before operating! The wheels and foot must be installed to provide proper clearance for ventilation. Failure to provide clearance may result in severe overheating and may cause damage to the charger and the surrounding area.

Positive

Booster Cable

Negative

Cable from Charger

The charger must be fully assembled

Assembly

1. Assemble the charger according to the following instructions and Figures 5 and 6.

2. Carefully, remove the charger and parts bag from carton.

3. Stand charger upright and rotate handle upward aligning mounting holes on handle to holes on cabinet. Secure with self-tapping screws and tighten all handle screws (see Figure 5).

Tighten down Screws to Cabinet

Figure 5 – Install Handle

4. Remove clamp holders from hardware bag. Snap the two pieces together onto the handle and secure with 2 machine screws (see Figure 6).

Figure 6 – Install Clamp Holder

5. Assembly is now complete.

Page 5

Westward Operating Instructions and Parts Manual

Models 1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Operation

6/12 V

START

12 V

HIGH

OFF

12 V

MEDIUM

6 V

HIGH

12 V

LOW

6/12 V

START

12 V

HIGH

OFF

12 V

MEDIUM

6 V

HIGH

12 V

LOW

MINIMUM START

24 V

HIGH

12 V

HIGH START

OFF

6 V

HIGH START

12 V

MEDIUM

E N G

S H

1JYT9A

Figure 7

CHARGING TIME INSTRUCTIONS

1. Determine battery percent of charge (or specic gravity) with hydrometer or electronic tester.

2. Note specic gravity or percent of charge on the following chart. Use column nearest the Ammeter reading observed.

Hydrom-

Reading (Battery

Specic

Gravity)

Ammeter Reading

eter

1.265

1.225

1.190

1.155

1.120

Battery

Tester Reading (Percent Charge)

100%

75% 50% 25%

6 Volt

Battery

Charging

Time

(Minutes)

Full Charge Full Charge

27 55 85

110

12 Volt Battery

Charging

Time

(Minutes)

60 40 20

3. Charge battery for the time indicated on the chart. A more precise method of determining length of charge time requires the use of the following formulas, the reserve Capacity or Ampere Hour rating of the battery, and the percent of charge needed to bring the battery to full charge.

400

800 1200 1600

1JYU1A 1JYU2A 1JYU3A

4. If the only battery rating known is Reserve Capacity, you must rst convert it to Ampere Hours using the following formula:

Amp hour Reserve size of

Capacity (min)

15.5

NOTE: Express the percent of charge needed as a decimal (25% = .25). Amp output for charge rate settings: 12V Low = 2 Amps, 12V Medium = 40 Amps, 6 or 12V High = 60 Amps.

Percent of charge needed = 25% or .25.

Battery

Example: Reserve Capacity of

.25 x 45.5

x 1.25

Battery = 60 Minutes

hour

15.5 45.5 Ampere

5. With the battery Ampere Hour rating and the percent of charge needed to bring the battery to full charge, use the following formula to determine length of charge time of battery selected on charger:

Amp Hour Rating

% of Charge

Needed

Amp Setting

1.25

Hours

Charge

6. Plug charger supply cord into 120V, 60 Hz, outlet, set charging rate selector for ammeter reading closest to chart column used, timer will shut charger OFF when charging cycle is complete.

CHARGER CONTROLS

MODELS 1JYT9A & 1JYU1A

Refer To Figure 7

The switch on the front of your charger

is used to select the voltage and rate of charging. Listed below are the settings and typical uses for each. (Clockwise from top):

1.42 Hours

To Charge

Page 6

Westward Operating Instructions and Parts Manual

Westward

Battery Chargers

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Operation (Continued)

E N G

S H

OFF - Shuts o power to charging

portion of charger; does not remove power from the entire unit.

6V High - Provides up to 60 amps for 6 volt batteries, 40 amps on 1JYT9A.

12V Low - Provides a charge of 2 amps for 12 volt batteries. Good for small batteries on motorcycles, lawn equipment, etc. Also used for restoring sulfated batteries by charging for extended periods at low rate.

12V Medium - Provides a maximum charge of 40 amps (N/A for 1JYT9A) for charging calcium-style batteries or others that cannot withstand higher rates of charge.

12V High - Provides up to 60 amps, 40 amps on 1JYT9A for 12 volt batteries.

6V & 12V Engine start - This setting is used for starting 6V & 12V vehicles.

MODEL 1JYU3A

Refer To Figure 7

6V High & Start - Provides up to 60 amps for charging and starting 6 volt batteries.

12V Medium - Provides a maximum charge of 40 amps for charging calciumstyle batteries or others that cannot withstand higher rates of charge.

12V High & Start - Provides up to 60 amps charging and starting power for 12 volt batteries.

24V High - Provides up to 30 amps charging and starting power for 24 volt batteries.

MODEL 1JYU2A

Your model 1JYU2A battery charger is a manual to fully automatic charger with a 2 hour timer (for use in manual mode), and an innite amperage control that allows a selection of any charge rate up to 60 amps. It has a test feature that allows you to test for percent of charge, alternator performance, and problem conditions such as sulfated or shorted batteries.

TIMER/MODE SELECTOR

The 1JYU2A TIMER/MODE SELECTOR sets the charger to manual mode and allows the selection of any charging time up to 120 minutes. In manual mode (no time set in), charging is controlled by the RATE SELECTOR. When the time is up, the charger will switch to a 15 amp automatic on/o mode that will start and stop the charger, as the battery requires, until the battery is fully charged. The charger will shut o when the battery is at full charge. If left connected, the charger will continue to monitor the battery and will automatically begin charging again if the battery drops below full charge. To charge a battery in automatic mode, return the timer to automatic (no time set into the timer). THE RATE SELECTOR will no longer be in control of charging. The automatic charge rate is 15 amps.

Do not charge motorcycle and garden tractor, etc. batteries in automatic mode. Charge in manual mode only, 2 amps maximum.

VOLT SELECTOR

Allows the selection of 6 Volt or 12 Volt charging. This switch also has a center OFF position to turn the charger OFF.

GENERAL CHARGING INFO FOR ALL MODELS

As the battery becomes more fully charged, the rate of charge tapers down. Depending on the battery percent of charge, the amperage that the charger delivers when starting to charge will vary. It will usually be less than the amperage selected unless the battery is almost fully discharged.

Always make sure that the selection you make matches the voltage of the battery being charged.

When charging small 12 volt batteries, like those used in garden tractors, snowmobiles, motorcycles, and ATV's, always select the 12 volt/2 amp setting. Small batteries like these can be damaged by higher rates of charge.

ENGINE START FUNCTION

For starting engines, connect the charger as you normally would, charge the battery for 5-10 minutes, set selector to start and then crank the engine.

When the starter engages, the charger will deliver starting power to supplement the battery to start the vehicle. Do not crank for more than 5 seconds as overheating of the vehicle starter, cables, and battery charger can occur. After allowing to cool for 3-4 minutes, cranking can be repeated. The charger is protected from overheating by a thermal protector. This is for the protection of both the charger and the vehicle. If the thermal protector trips, wait until the charger resets automatically (about 3-4 minutes) and resume cranking.

Page 7

Westward Operating Instructions and Parts Manual

Models 1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Operation (Continued)

NOTE: Problems in a vehicle's fuel, ignition, or other systems may prevent the vehicle from starting. The problem area will need to be serviced before the vehicle can be started.

AMMETER

AMPS

Figure 8

The ammeter on the front of the charger (see Figure 8) indicates the amount of amperes owing from the charger into the battery. As the battery nears full charge, the charge rate lessens and the ammeter needle moves towards lower ampere values. Model 1JYU2A also has green and red lights installed within the ammeter. The green light is lit when the battery is at full charge. The red light indicates that the battery cables are connected backwards (takes six seconds before the light will come on).

When the battery being charged is cold (temperatures less than 32ºF (0ºC) the battery will not accept high rates of charge until it warms up. The initial charge rate will be low and, as the battery warms up through charging, the rate will increase.

The same conditions exist if the battery being charged is sulfated. Sulfated batteries cannot accept high charge rates because the internal plates of the battery are coated with lead sulfate. This occurs when a battery is left in a discharged state for a long time. This

battery condition can sometimes be cured. The battery can have at least some of the sulfate removed by charging on the 2 amp setting (12 volt only) for a long period of time. Refer to the battery manufacturer's instructions for the proper methods of removing sulfate.

When the battery being charged has a short circuit, the ammeter will show that the charger is putting out full current. If, after 5-10 minutes, the needle has not moved, unplug the charger and discontinue charging.

NOTE: If the needle drops to zero, the internal circuit breaker has tripped and will reset automatically after 3-4 minutes. Use a voltmeter and read the voltage of the battery. If the voltage is under 11.5 volts, the battery is probably defective and should be serviced or replaced. If the voltage reads over 11.5 volts, plug the charger back in and continue charging. If, after 15-20 minutes, the needle on the meter still has not moved, repeat the voltmeter test. If no change in voltage has occurred, the battery needs service or replacing.

During Engine Start, the needle will move into the red Engine Start section of the meter. This will occur when the vehicle starter is engaged.

VOLTMETER (1JYU3A ONLY)

Figure 9

VOLTS

The voltmeter (Figure 9) will indicate voltage whenever the charger is turned on, or when the clamps are connected to a battery. If connected to a battery and on, it will read the combined voltage of the battery and the charger. If you get no reading when connected to a battery, check your connections and/or your battery.

TEST METER/VOLTMETER (1JYU1A AND 1JYU2A ONLY)

100

LOW

DC VOLTS

HIGH

Figure 10

The combination test meter/voltmeter on the front of the charger (see Figure

10) is used to read the voltage across the battery charger clamps.

In normal operation, without the Test Switch depressed, the meter reads from 0-20 DC volts, on the lower scale of the meter. Using this part of the meter, during charging, the voltages should read:

6 Volt Batteries 6.5 to 8.5 Volts

12 Volt Batteries 13.5 to 16.5 Volts

24 Volt Batteries 27.0 to 33.0 Volts (1JYU3A Only)

If the voltmeter reads outside of these voltages, refer to the listings below for possible battery conditions:

E N G

S H

Page 8

Westward Operating Instructions and Parts Manual

Westward

Battery Chargers

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Operation (Continued)

E N G

S H

Volts Low, Amps High

Probable Shorted Battery – Replace

Volts Low, Amps Low

Poor Connection or Frozen Battery

Volts High, Amps Low

Battery Cold or Sulfated – Reduce charge rate and charge longer.

After charging is complete, the voltmeter should read the full charge voltage of the battery. This is normally higher than the rated battery voltage.

TEST SWITCH (1JYU1A AND 1JYU2A ONLY)

By depressing the Test Switch, the voltmeter changes into a more precise mode. This precision is necessary to read battery charge levels.

BATTERY PERCENT OF CHARGE TEST (12 VOLT ONLY) 1JYU1A AND 1JYU2A ONLY

1. With the charger OFF and clamps properly connected to the battery, depress the Test Switch and read the Battery Percent of Charge on the top left scale of the Test Meter.

2. If the battery has been recently charged or is in a vehicle that has been run recently, there is probably a “surface charge” on the battery. This will give a falsely high reading on the Percent of Charge Test. Remove the “surface charge” by turning on the vehicle headlights for 3 or more minutes. Allow the battery to sit for 1 minute. Then re-test the Battery Percent of Charge.

ALTERNATOR TEST (12 VOLT ONLY) 1JYU1A AND 1JYU2A ONLY

1. With charger OFF and clamps properly hooked to the battery, start the engine and while running it at fast idle, depress the Test Switch.

2. Read the alternator condition on the Alternator Test scale at the upper right section of the Test Meter. The battery should be in a good state of charge before attempting this test.

3. The three zones of the meter indicate the following:

OK –Charging system is

performing properly

LOW –Loose fan belt, or voltage

regulator and/or alternator faulty

HIGH –Faulty voltage regulator or

wiring harness

NOTE: This type of repair work is rather specialized. It may require additional tests on additional instruments for complete diagnosis.

IMPORTANT: The charger must be turned OFF to perform the tests. If attempting to test with the charger turned ON, the results will be meaningless.

TIMER CONTROL

The timer on the front of your charger allows you to set a time to charge. Turn the knob clockwise to the time desired.

When setting the timer for times less than 20 minutes, turn the knob past the 20 minute setting and then turn back to the time desired. After the set time has elapsed, the timer shuts o the charger. Refer to the Charging Time Instructions on page 5 in this manual to determine the proper time to set.

Turning the timer knob counterclockwise to the Hold position turns the charger on, but the timer will not return to the OFF position. Use this position only when you do not want the charger to turn o automatically.

Maintenance

Do not leave the

battery unattended for long periods of time when the timer is in the hold mode, as damage to the battery may occur.

Disconnect all

power before attempting to service or remove any components!

This battery charger will require little maintenance if properly used. For more ecient operation, it is advisable to blow the dust o the louvers, rectier, and transformer at least once or twice a year, depending on amount of use. The cover is held in place by screws, and is easily removed for maintenance.

Page 9

Westward Operating Instructions and Parts Manual

Models 1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Wiring Diagrams

Negative Cable Assembly (Black)

Positive Cable Assembly (Red)

Power

Cord

Green

White

Rectier

Circuit

Breaker

Fan

Center Tap

Black

Transformer

Black

Thermal Breaker

Black

Rate Selector

Yellow

Black

Orange

Red

Switch

Blue

Ammeter

Timer

Black

E N G

S H

Figure 11 - Model 1JYT9A

Black

Page 10

Westward Operating Instructions and Parts Manual

Westward

Battery Chargers

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Wiring Diagrams (Continued)

N G

Negative Cable Assembly (Black)

Black

Rate Selector

Switch

Timer

Black

Test Switch

Circuit

Breaker

Positive Cable Assembly (Red)

Power

Cord

Green

White

Rectier

Fan

Center Tap

Black

Transformer

Thermal Breaker

Black

Yellow

Black

Orange

Red

Blue

Ammeter

White

Voltmeter w/circuit board

Black

Blue

Black

Figure 12 - Model 1JYU1A

Page 11

Westward Operating Instructions and Parts Manual

Models 1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Wiring Diagrams (Continued)

Selector

Negative Cable Assembly (Black)

Positive Cable Assembly (Red)

Power Cord

Ground

Green

Circuit

Breaker

Rectier

Secondary Lead

White

Black

Switch

Secondary Lead

Transformer

Fan

Red

Blue

Black

Black White Orange

Black

Thermal Breaker

White

P C B

Center Tap

Red

Brown Violet

White

Ammeter

Green

Yellow

Timer

White

Blue

Test Switch

Voltmeter

Black

E N G

S H

Black

Figure 13 - Model 1JYU2A

Page 12

Westward Operating Instructions and Parts Manual

Westward

Battery Chargers

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Wiring Diagrams (Continued)

N G

Negative Cable Assembly (Black)

Black

Rate Selector

Switch

Timer

Black

Circuit

Positive Cable Assembly (Red)

Power

Cord

Green

White

Rectier

Breaker

Fan

Center Tap

Black

Transformer

Thermal Breaker

Yellow

Red

Blue

Black

Ammeter

White

Voltmeter w/circuit board

Black

Figure 14 - Model 1JYU3A

Page 13

Westward Operating Instructions and Parts Manual

Models 1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Troubleshooting Chart

Charger inoperative

1. Power cord not plugged into outlet

2. Plug not making good connections in outlet

3. No power at outlet

4. Defective power supply cord or plug

5. Open internal connection

6. Defective timer switch

7. Defective rectier, transformer, circuit breaker, ammeter or switch

8. Circuit breaker has tripped

noitcA evitcerroC)s(esuaC elbissoPmotpmyS

1. Plug power cord into outlet

2. Inspect prongs of plug and straighten if necessary. Replace outlet receptacle if defective

3. Check supply fuses or circuit breaker. If necessary, replace or reset

4. Check electrical continuity of cord and plug. Replace if defective

5. Inspect all internal electrical connections. Reconnect or tighten any that are loose

6. Replace defective timer

7. Replace defective part

8. Set timer to OFF. Wait a few minutes for circuit breaker to automatically reset. Check cause of excessive current and eliminate it

E N G

S H

9. Defective cable or clamp

Charger will not charge in one or more of the switch settings

Charger operates properly, but does not return to OFF after timer is set

Charger operates, but charging circuit won't turn OFF when timer is in OFF position

IMPORTANT: Servicing must be performed by qualied service personnel.

Defective selector switch

Defective timer switch

9. Check continuity of each cable and clamp. Replace if defective

Replace switch

Replace timer

Page 14

Westward Operating Instructions and Parts Manual

For Repair Parts, call 1-800-323-0620

24 hours a day – 365 days a year

Please provide following information:

-Model number

-Serial number (if any)

-Part description and number as shown in parts list

Address parts correspondence to: Grainger Parts Operations P.O.Box 3074 1657 Shermer Road Northbrock, IL 60065-3074 U.S.A.

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Figure 15 – Repair Parts Illustration for Battery Chargers

Page 15

Westward Operating Instructions and Parts Manual

Repair Parts List for Battery Chargers

Servicing should be performed by qualied service personnel only.

Performed by qualied service personnel. Replacement Parts List for models 1JYT9A, 1JYT1A, 1JYU2A, 1JYU3A

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Reference

9 “-” Negative Clamp with Cable and Strain Relief TT249261666G

10 “+” Positive Clamp with Cable and Strain Relief TT249260666G

“+” Positive and Negative Clamps with Grips TT249066666G

G000332145TTylnO feileR niartS”+,-“

13 Voltmeter/Test Meter for 1JYU1A and 1JYU2A TT246134666G

NOTE: No voltmeter on 1JYT9A.

14 Ammeter for 1JYT9A & 1JYU1A & 1JYU3A TT247133666G

G666773642TTylnO 2AUYJ1 rof hctiwS51

17 Rotary Switch for 1JYT9A & 1JYU1A & 1JYU3A TT246408666G

G666408568TTylnO 2AUYJ1 rof ylbmessA BCP71

∆ 1G050606044TTlenaP thgiR ∆ 1G050706044TTlenaP tfeL ∆ 1G666243244TTeldnaH ∆ 1G666620213TTredloH pmalC

ytitnauQrebmuN traPnoitpircseDrebmuN

1G050395044TTesaB1 1G666310860TTsbuH )2(2 1G666940314TTsbuH )2( dna sleehW )2(3 1G666340314TT)2( sbuH htiw elxA4 1G666410613TTedalB naF5

1G666095214TTtekcarB gnitnuoM naF6 1G666140612TTrotoM naF7 1G666213842TTfeileR niartS htiw droC rewoP8

1 1 1 1

1G666286568TTylbmessA reifitceR11 1G666904642TTrekaerB tiucriC21

1 1G666531642TTylnO 3AUYJ1 rof retemtloV31

1G666421742TTylnO 2AUYJ1 rof retemmA41 1

1 1G1666140642TTb (Timer) onK lortnoC61 1G666261042TT Control Knob (Rate Selector)61

1G666273642TTylnO 2AUYJ1 rof remiT81 1G666372642TT3AUYJ1& 1AUYJ & 9ATYJ1 rof remiT81 1G666732642TT2AUYJ1 & 1AUYJ1 rof )tseT(hctiwS91 1G666385044TT9ATYJ1 rof lenaP tnorF02 1G666185044TT1AUYJ1 rof lenaP tnorF02 1G666485044TT2AUYJ1 rof lenaP tnorF02 1G666285044TT3AUYJ1 rof lenaP tnorF02

1G666760213TT)erawdrah htiw( tooF tnorF12 1G666014642TTrekaerB lamrehT22

1G888838568TT9ATYJ1 rof remrofsnarT32 1G888538568TT2AUYJ1 & 1AUYJ1 rof remrofsnarT32 1G888118568TT3AUYJ1 rof remrofsnarT32

E N G

S H

(∆) Not Shown. (+) Included with reference number 8. (-) Included with reference numbers 9 and 10.

Page 16

Wesrward Operating Instructions and Parts Manual

Westward

E N G

S H

LIMITED WARRANTY

WESTWARD ONE-YEAR LIMITED WARRANTY. Westward

Electric Mfg. Co. (Westward) to the original user against defects in workmanship or materials under normal use for one year after date of purchase. Any part which is determined to be defective in material or workmanship and returned to an authorized service location, as Westward designates, shipping costs prepaid, will be, as the exclusive remedy, repaired or replaced at Westward’s option. For limited warranty claim procedures, see PROMPT DISPOSITION below. This limited warranty gives purchasers specic legal rights which vary from jurisdiction to jurisdiction.

LIMITATION OF LIABILITY. To the extent allowable under applicable law, Westward’s liability for consequential and incidental

damages is expressly disclaimed. Westward’s liability in all events is limited to and shall not exceed the purchase price paid.

WARRANTY DISCLAIMER. Westward has made a diligent eort to provide product information and illustrate the products in

this literature accurately; however, such information and illustrations are for the sole purpose of identication, and do not express or imply a warranty that the products are MERCHANTABLE, or FIT FOR A PARTICULAR PURPOSE, or that the products will necessarily conform to the illustrations or descriptions. Except as provided below, no warranty or armation of fact, expressed or implied, other than as stated in the “LIMITED WARRANTY” above is made or authorized by Westward.

PRODUCT SUITABILITY. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use

of products for certain purposes, which may vary from those in neighboring areas. While Westward attempts to assure that its products comply with such codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, review the product applications, and all applicable national and local codes and regulations, and be sure that the product, installation, and use will comply with them.

Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you; (b) also, some jurisdictions do not allow a limitation on how long an implied warranty lasts, consequentially the above limitation may not apply to you; and (c) by law, during the period of this Limited Warranty, any implied warranties of implied merchantability or tness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.

PROMPT DISPOSITION. Westward will make a good faith eort for prompt correction or other adjustment with respect to

any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, rst write or call dealer from whom the product was purchased. Dealer will give additional directions. If unable to resolve satisfactorily, write to Westward at address below, giving dealer’s name, address, date, and number of dealer’s invoice, and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was damaged in transit to you, le claim with carrier.

Battery Chargers

Battery Chargers covered in this manual are warranted by Westward

1JYT9A, 1JYU1A, 1JYU2A and 1JYU3A

Manufactured for Grainger International, Inc. 100 Grainger Pkwy., Lake Forest IL 60045 U.S.A.