wheelhorse battery charger service manual for wheelhorse model e-141 electric tractors 810274

8/7/2019 WheelHorse Battery Charger service manual for WheelHorse model E-141 electric tractors 810274

http://slidepdf.com/reader/full/wheelhorse-battery-charger-service-manual-for-wheelhorse-model-e-141-electric 1/16

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CONTENTS

CHARGER DESCRIPTION AND OPERATION

General Information ........................... .

Operating Instructions .......................... .

Maintenance and Storage ....................... .

Component Identification ....................... .

Operating Sequence & Circuit Description .......... .

Schematics & Wiring Diagrams ................... .

Tractor Charging Circuit ........................ .

TROUBLESHOOTING ................................. .

General ..................................... .

Manual Advance Screw ........................ .

Troubleshooting Checklist ....................... .

Troubleshooting Sequence

Page

2-6

2

2

3

3

3-4

5

6

6-11

6

6

6

7

Special Service Procedures ....................... 7-8

Testing Components ............................ 8-11

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

-1-



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RAM Operate Circuit - Timer I I (4-terminal)connector, Wire 1, timer Ll (2.terminal) can·

nectar, internal timer switch contacts, timerVSO connector, Wire 12, DC relay NO can·

tacts, Wire 13, timer RAM connector, RAM,timer L2 connector.

FAULT Light Circuit - Timer L1 (4-terminal)connector, internal timer switch contacts,timer FAULT connector, Wire 17, FAULT light,Wire 16, DC relay NO contacts, Wire 6-01,timer l2 connector.

c. The RAM advances the timer switch until thecontacts between L1 (2-terminal) an d VSOopen. This stops the RAM an d disconnects the

Fault light. At the same time the timer contacts between L1 (4-terminal) an d TM dose.

Power is supplied to the timer motor and

transformer an d charging begins. The redNOTICE light illuminates.

Timer Motor Circuit - Timer I I (4-terminal)connector, internal switch contacts, timer TMconnector, timer motor, timer L2 connector.

Transformer Circuit Timer I I (4-terminal)connector, internal switch contacts, timer TMcan nectar, Wire 11 (2), multi-pin connector

pins 7&

8, transformer primary winding,multi.pin connector pins 1 & 2, Wire 5 (2).

NOTICE Light Circuit - Timer I I (4-terminal)connector internal switch contacts, timer TMcan nectar, Wire 10-01, NOTICE light, Wire6-02, timer l2 connector.

3, The transformer secondary steps the AC voltage

down and two diodes are used to rectify the ACto a pulsating 40 VDC to charge the power pack.The transformer has an additional resonant

winding in parallel with a .4 mfd capacitor, whichregulates the transformer's output. This circuitkeeps the DC voltage constant while charging

current diminishes as power pack voltage risestoward the full charge level.

4. When the charger has restored 80% of fullcharge to the power pack (Battery voltage reaches40 volts), the transistor in the tractor's "Brain ina Box" (See 1, preceeding) turns off, interruptingpower to the DC relay coil. The relay "drops out",the orange 80% CHARGED light illuminates, an d

the RAM advances the timer switch to where 6hours of charging time remains.

80% CHARGED Light Circuit - Timer L1 (4-terminal) connector, internal switch contacts, timer TMconnector, Wire 10-01, NOTICE light, Wire 10-02,SO% CHARGED light, Wire 14, DC relay NC contacts, Wire 6-01, timer l2 connector.

FAULT INDICATOR

10 hours after the charging cycle begins, the

timer switch FLT contacts close. If the DC relay

has NOT dropped out by this time (80% charge

level NOT reached) the red FAULT light will illuminate, an d pawer to the timer and transformer

is cut off. If this occurs, the charger should be

disconnected, as the energized DC relay coil willgradually discharge the pawer pack.

FAULT Circuit - Timer L1 (4-terminal} connector, internal timer switch contacts, timer FLTconnector, Wire 17, FAULT light, Wire 16, timerL2 connector.

RAM Operate Circuit - Timer I I (4-terminal) copnectar, Wire 1, I I (2-terminal) connector, internalswitch contacts, timer VSC terminal, Wire 15,DC relay NC contacts, Wire 13, timer RAM connector, RAM, timer L2 connector. t

RAM Stop Circuit - Timer switch contacts between

L1 (2-termina1) and VSC connector open at 6 hourscharging time remaining.

5. The remaining 20 % of charge is added to thepower pock during the final 6 hour charging

period. During this time the timer motor slowlyadvances the timer switch to the end of the

charge cycle, the timer stops, the orange and

red lights go out, and the green USE light illuminates. If the charger is left connected, the

charger will automatically restart when the power

pack's voltage drops below 37 volts.

USE Light Circuit - L1 (4-terminal) connector,internal timer switch contacts, FLT connector,Wire lS , USE light, Wire 2S, Wire 14, DC relay

NC contacts, Wire 6-01, L2 connector.

RAM RECYCLE, CHARGING INTERRUPTED

The charger is set up to prevent over/undercharg-

ing when the normal charge cycle is interrupted.The AC relay serves this function by supplying power

to the RAM, which advances the timer switch to th e

correct place in the charging cycle. The DC relay

powers the RAM during the actual charging cycle.If the charger is disconnected or a power failureoccurs during charging, one of the following willoccur:

1. Charger in USE Cycle, Power Pack above 37

Volts - Green USE light will illuminate again

when reconnected.

2. Charger in SO% CHARGED Cycle - RAM willadvance timer switch to USE Cycle when reconnected; the final 6 hour charging period will not

take place in this case. If the power pack isbelow 37 volts when reconnected, a new charging

cycle will begin (Circuit an d operation as described in 2b, preceeding).

RAM Operate Circuit - I I (4-terminal) connector,internal timer switch contacts, timer lNC connector, Wire 20, Wire 19, RAM, timer L2 connector.

RAM Stop Circuit Timer switch contacts between

I I (4-terminal) an d lNC connector open when

advanced to USE position; timer switch contactsbetween Ll (4-terminal) and COil close. Thissupplies 120 VAC to the coil of the AC relay

(Wire 26 & 7). When the relay "pulls down", the

contacts connecting Wire 19 & 20 ar e opened

an d contacts between Wire 8 & 9 ar e closed. Thiskeeps power supplied to the relay coil, holdingit down an d preventing the AC relay from oper-ating the RAM, unless the charger is again disconnected.

3. Charger in NOTICE, Charging in Process Cycle -RAM will advance timer switch to the USE Cyclewhen reconnected; since power pack was below

37 volts when power wa s interrupted, a new

charging cycle will start (RAM Operate & StopCircuits same as for SO% CHARGED Cycle, above;

Normal charge cycle start circuit as describedin 2b, preceeding).

-4-



@

®

GROUND

<3) NEUTRAL

VS

2A

@~ - + - - - - - - - - - - - - - - - - ~ ~ - - - - - L . - o

PIN 6

- - - - - - < ~ ~ o

L2-4 CD

SEE CABLE

DIAGRAM

ill4l-_P_IN<' ~ I N 7 ®

PIN 2

80%

LATCH

____ ~ ~ I A ~ I ~ ' C ~ ~ ~ ~ . oVS

' ----. 2C 2B

@ ) ~ . ~ V 2B 2C VUVv

'--__________________-'@ LATCH @

o OR 0 WIRE"S 0 MOTORS 0 LIGHTS VMARKED ON TIMER

FIG. 4. Charger Schematic - Control Section

PIN:3 tf'2\

FNM ISAMP

FUSE

® GREEN YELLOW 'e;J

r - - ; " ; ; ; ; ' ; : = ~ - - - - " " : : J VS RELAY

PIN 9 COIL

ORANGE

®

BWECHARGING

TRANSFORMER

PIN 6

PIN I

PIN 2 ....H ~ - - - - - . , . PRIMARYWINDING

PIN 7 ..........>--- - - - - '

PIN 8

REO

C}RED

WHITE

SECONDARY

WINDING

4 ....f660VAC

RESONANT WINDING

HEAT SINK#1

FIG. 5. Charger Schematic - Output Section

-5-



FIG. 6. .

Wiring Diagram



NOTES

! ALL WiRE COlORS alAO< UNLESS OTHERWISE MjiEO

2. NEGATlY( A'iD POSITIvE CIRCUITS ISOLATED FllWMCHASSIS GROVNO EXCEPT WIRE.3.3 AT CHARGER: If£CESSORY PlJG

3. CONTROL eaxo. SYM8Ol. ...< -E... l'lOtCATES CC#4NECT!O'" MAOE AT

........n·wu:"e: CONNECTOR AT BOTTOM OF SOXb. PI1\! MID SOCKET NUM9£RS OF MUlTI'Wfi1!£

CONNECTOR SAME AS WIRE NUMBERS

t CONTROl.. BOX INTERNAL CIRCuITS SrfOWN AREINCOMPLETE USE J'Cft CIReVI':' ~ R : A C I N ( , PURPOSES ONL'o'

oj INTERNAL SERVICE OF CONTROl,.. BOX NOT TO

BE PERFURMEO UNt.£SS AUTHORIZED 8Y

WHEEL HORSE" PRODUCTS. INC

21-02

ORANGE I

I

24 R£D 24 ~ E O

21-01 22'-01

j 2 : j ~ i . I

, - - - - - - ~ " " " ' - - _ _ l : S ! C l J W ~ C H f - - - - - ' ~ ~ - - I ~ : L"'0. , , ~ ~ I

1 ,-, "TA I l - .... /

-::. R ::LIGHTS :. R:: :

f \ I '

I

BALANCEMETER

({

At .OR!vE

MOrOR

.z••••••••••••••••• <4

FIG. 7.

.................._-_ .._---- - - - ,

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ELECTRONIC loon

... 36V : CHARGER

r - I - o r - O - R - O V - ' - ' R L . ' C O ' - ' A O " ~ AND, ALARM CONTROL

ALARM

-_ - J : ~ : J , - - -,,<.

E·141 Wiring Diagram

C8-',0.CHARGER/

ACC.c.•

!

: 21-02

iOAANGE

""0



TRACTOR CHAIGING CIRCUIT

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TROUBLESHOOTING SEQUENCE

1. Connect the charger to the tractori if a "click" isheard (DC relay pulling down) the Brain in aBox is supplying the signal to start the charging

cycle. Proceed to Step 2.

If the charger does not "click":

a. Batteries are above 37 volts (80% Charged)

- The Brain in a Box will not supply the

voltage for the DC relay until the power pack

is discharged to below 37 volts. To continue

this test, discharge the power pack as necessary by operating the tractor/mower. Power

pack voltage should then be between pins1 and 5 of the tractor's charger/accessory

receptacle, an d the "click" should be heard

when the charger is connected.

b. Batteries severely discharged - Check the

voltage between pins 1 and 5 of the tractor's

charger / accessory receptacle. If 30 volts or

less, there is probably not enough voltage tooperate the DC relay. Manually start the

charger (See Manual Advance Screw, pre-

ceeding). Once the power pack is brought up

to normal levels, the charger should operate

properly.

c. Defect in charger - Check the voltage be-tween pins 1 and 5 on the tractor's charger/

accessory receptacle. If above 30 volts, defect

is in charger. Separate the charger into tw o

sections an d check DC relay and connecting

wiring. Also see "Tight Relay" under "Special

Service Procedures".

d. Defect in tractor - If the power pack is below

37 volts bu t there is no voltage between

pins 1 and 5 on the tractor's charger /accessory receptacle, the defect is in the

tractor. Check the wiring leading back to

the "Brain in a Box", the resistor module

(100 Ohms between pins 1 & 9), and wiring

between the power pack an d charger /

accessory receptacle. If OK, replace theBrain in a Box.

2. Disconnect the DC output cord from the tractor,

then plug the charger into a 120 VAC power

source. The charger should "click" (AC relay pulling down) and the green USE light should illuminate. If this does not occur immediately, the RAM

should operate to advance the timer to this position (End of Cycle). The red NOTICE an d orange

lights should illuminate during this period and

the sound of the RAM should be heard, followed

by the green light and the click of the AC relay.

Proceed to Step 3.

If the charger does not "click":

a. Disconnect the power cord and turn theManual Advance Screw Va turn. Reconnect the

power cordi if the charger now operates

properly, the timer switch was stuck. Continue with this troubleshooting sequence, then

run through it again from the beginning tose e if the problem repeats itself. Also see

"Revised Capacitor Mounting" under "Special

Service Procedures".

b. If Step 2a did not correct the problem, sepa-

rate the charger into two sections and checkthe AC relay and connecting wiring. Also see

"Tight Relay" under "Special Service Procedures". If OK, replace the timer.

3. Disconnect the AC power cord and connect the

DC output cord to the tractor. Reconnect the AC

power cord. The RAM should operate, the red

FAULT light should illuminate for 1-2 seconds,

then the red NOTICE light should come on as the

RAM stops. The hum of the transformer should

also start. Proceed to Step 4.

If the correct action does not occur:

a. Charging transformer hum starts, but one or

both lights do not illuminate. Replace light or

lights, as applicable.

b. RAM and lights operate, bu t transformer doesnot start humming. Separate the charger intotwo sections and check the transformer, diodes and connecting wiring.

c. RAM does not operate (green light remains

on). Replace timer.

4. Disconnect the DC output cord from the tractor.

The orange 80% CHARGED light should illuminate. The RAM may also operate to advance the

timer switch to where 6 hours of charge time

remain. (The orange and red lights will remain

on, except for a brief moment when the green

light illuminates). If the RAM does not operate

now, the timer will be advanced in Step 5. Proceed to Step 5.

If the light does not illuminate, separate the

charger into two sections and check the DC relay

NC contacts and orange light connections. If OK,replace the orange light.

5. Disconnect the AC power cord, then reconnect it.The RAM should advance the timer to the en d of

the charging cycle, where the RAM will stop, an dthe green light will come on. The "click" of the

AC relay pulling down will also be heard.

If the timer does not advance as described, checkthe AC relay NC contacts and connecting wiring.

If OK, replace the timer.

This completes the normal troubleshooting sequence .

Because this process rapidly moves the charger

through a complete charging cycle, it is possible anintermittent fault ma y not be discovered. A few special

circumstances are covered in the following section.

SPECIAL SERVICE PROCEDURES1. Erratic Charger Operation - If the charger runs

through a charge cycle, stops for a period of time,

then runs for a few hours, and keeps repeating

this pattern (tractor not being used in between),

it is an indication that there may be a fault inthe Brain in a Box. Before replacing the box,check the power pack voltage every hour or soand observe if it is dropping rapidly. This would

indicate a high resistance short or a battery with

shorted cells. Also run the charger through the

Troubleshooting Sequence tocheck its

operation.

2. Charger Completely Dead (Main Fuse OK) -Since the charger cannot be cycled, separate itinto two sections. Make a good visual inspectionfor an obvious fault. Component resistance checksfor an open circuit will be necessary if the fault

is not evident.

3. Revised Capacitor Mounting - Initial production

run chargers used two securing straps around the

capacitor. On some chargers, the capacitor islow enough to rest on the case of the RAM. Thisca n jam the timer so the RAM will not operate.

In this case, remove and discard the lower strap,

and slide the capacitor up as shown in Fig. 9.

-7-



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TRANSFORMER TEST, CHARGER DISASSEMBLED

Almost all transformer failures will be easy todetermine, since partial failures such as a winding

with a few shorted turns or an intermittent shortseldom occur. The three transformer failures are:

shorted winding, open winding, grounded winding.

A shorted winding will result in the transformer

"burning Up". The winding or windings will appearblack, (normal color is a reddish brown), there may

be a foul odor, an d possibly some evidence of melted

insulation. Repeated fuse blowing is also commonwith this type of failure. If the transformer appears

good, and the charger fuse blows repeatedly, a diode

or the capacitor may be shorted.

In the case of no DC output, check for an open

transformer winding. Be sure to check all wires ofthe DC output cable for continuity (zero resistance)before checking the transformer.

1. Set the YOM for resistance, on the lowest (Rxlor Rxl0) scale, an d "zero" the meter. Remove allpower to the charger unit.

2. Primary Winding Check - Touch the meter leadsto pins #2 an d 7 of the multi-pin connector.

Resistance should be around zero; if it is infinity(co) the primary winding is open. (Pin numbers

ar e marked inside the connector).

3. Secondary Winding Check - The secondary transformer leads are secured to the diode heat sinks(metal plates around each diode) with a screwan d nut. Touch a meter lead to each screw. Re-sistance should be around zero; if it is infinitythe secondary winding is open.

Next, touch one meter lead to pin #6 or 7 inthe DC output cable, an d the other lead to one

of the secondary transformer leads secured toa heat sink. Resistance should be around zero.If it is infinity, the center ta p off the transformer

secondary is open.

4. Resonant winding check - Disconnect one of thered resonant winding leads from the .4 mfd (microfarad) capacitor, an d touch a meter lead to each

resonant winding lead. Resistance should be near

zero; if it is infinity, the resonant winding is open.

If the transformer checks good, check for an open

diode or .4 mfd capacit?r.

To check for a grounded transformer, set the YOMon the highest resistance scale (Rxl K or higher). Touchone meter lead to the metal laminations of the transformer; touch the other meter lead to: (1) one of the

diode heat sinks, (2) pin #2 of the multi-pin connector,

(3) one of the red resonant winding leads. The meterreading should be infinity (CXl) in all cases. Anyresistance reading or a zero reading indicates agrounded transformer.

NOTE

The diode heat sinks ar e mounted in plasticexpansion nuts to insulate them from the case.Be sure to check for an infinity reading between

the mounting screw and the heat sink before

replacing the transformer.

PIN S1&2

MUlTI·PIN

CONNECTOR

SECONDARY

WINDING

CUT OFF TERMINAL

& STRIP BACK - CONNECT

TO DC OUTPUl CASlE(WHITE & SLACK WIRES)

0<

n======n RESONANT

WINDING(RED WIRES]

INSTAll 1110 RING

lERMINAl - SECURE

TO DIODE HEAl SINK

FIG. 14. Transformer Lead Identification

DIODE TEST

1. Set the YOM for resista nce, on the lowest (Rx 1or Rxl0) scale, an d zero the meter. Remove allpower to the charger unit.

2. Touch one meter lead to the diode case or heat

sink, and the other lead to the terminal with the

wire soldered to it; observe the meter reading.

Reverse the meter leads an d note the meter

reading.

a. A good diode is indicated by an infinity (CXl)

reading, which changes to near zero resistance reading when the meter leads ar e

reversed.

b. If the meter reading is zero with the meter

leads in both positions, the diode is shorted.

c. If the meter reading is infinity with the meterleads in both positions, the diode is open.

CAPACITOR TEST

1. Set the YOM for resistance, on the highest (Rx 1 Kor higher) scale, an d "zero" the meter. Removeall power to the charger unit.

2. Disconnect one of the red transformer leads fromthe capacitor.

3. While watching the meter, touch a meter lead toeach capacitor terminal. A good reading is indicated by the meter needle making a momentary

"jump" toward zero, then returning to infinity(CXl). If the meter has a very high resistancemeasuring capability, the meter needle will movetoward zero, then slowly rise to a high resistancereading near infinity. To repeat the test, momentarily short the two capacitor terminalstogether to discharge it.

If the meter needle does not move off infinity,the capacitor is open. If the meter reading iszero, the capacitor is shorted.

RELAY TEST

Visually check the relay contacts for signs of arcingor damage that would prevent electrical contact.There should be zero resistance between the NC contacts with no power applied to the relay coil. Thereshould be zero resistance between the NO contactswhen the relay is manually held down.

-10-



\\



PARTS LIST

VEHICLE IDENTIFICATION NUMBER 07-30EC01 (Formerly 8-1570)

Parts available only through Authorized Dealers.

- .. .....

ITEM

NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1819

20

21

22

23

24

25

26

27

28

29

30

When ordering parts always list Part No. and Description.

'Specifications subject to change without notice.}

PARTDESCRIPnON

NO. - ~ - - ...... ... ...----2708 Rubber Grommet, Cabinet Divider

100571 Plastic Tie

107239 Decal, Top

107241 Decal, End

107318 Back Panel - Cabinet

107320 Screen Wrapper - Cabinet

(Secured with 913252 Screws S.T. 6-32 x Yo)107321 Divider, Cabinet (Secured with 913118 Screw

10-32 x Yo, 920079 lockwasher # 10,915551 Nut 10-32)

107322 Divider Brace, Cabinet

107324 Handle (Secured with 913272 S.T. Screws10-32 x X)

107326 AC Relay (Secured with 913104 Screw 8-32 x Yo)

107327 Timer (Secured with 913118 Screw 10-32 x Yo ,920079 lockwasher # 10)

107328 AC Receptacle (Secured with 913252 S.T. Screw6-32 x Yo , 915536 Nut 6-32,920118 lockwasher #6 )

107329 Indicator lamp (White)*

107330 Indicator lens, Red

107331 Indicator lens, Orange

107332 Indicator lamp, Green

107335 Diode an d Heat Sink (Secured wi th 107180 PlasticExpansion Nut, .926554 Screw 8-18 x %.Transformer leads Secured to Heat Sink with913118 Screw 10-32 x X,920079 lockwasher # 10, 915551 Nut 10-32)

107339 DC Output Cable

107364 Decal, Caution

107366 Fuse Holder (Secured with S.T. Screw 6-32 x Yo)107367 Fuse, 15 Amp FNM

108630 Capacitor Bracket(Secured with 913272 S.T. Screw 10-32 x X)

516048 Transformer (Secured with 908001 Bolt X-20 x X,920081 lockwasher X, 915111 Nut X-20)

517991 Cord Clamp, DC Output Cable

518089 DC Relay (Secured with 913104 Screw 8-32 x Yo)518091 Pin Housing, Multi-Pin Con,nedor

(Transformer Section)

518097 Socket Housing, Multi-Pin Connector

(Control Section)523359 AC Power Cord

523392 Capacitor 4 mfd (Alternate 518233)

107319 End Panel, Cabinet....... ....

NO.

REQ'D .-- •.....-1

3

1

1

1

1

1

1

1

1

1

1

3

2

1

1

1

11

1

1

2

1

1

1

1

11

1

1

* Use a quick-drying adhesive such as Eastman 910 or loctite 495 to securelamp to Cabinet.

wheelhorse battery charger service manual for wheelhorse model e-141 electric tractors 810274

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