That didnt fix the charger did it? Im curious if it worked when you charged it into a battery. If the battery ws too dead it would have had the 3 blinking lilghts.
Is the beeping and and all 3 green lights common during a charging cycle. I have the same problem and it won"t charge in that state. A charge cycle is 1 light is lite at a time untill its fully charged. Thats how mine worked before it stopped charging. Will you share were you get your relyas from without having to buy 30 at a time like most suppliers. Thaanks for the video, the current thing sent me for a loop.
After a few hard lessons with intelligent battery chargers I always use a flat battery on the output side with a bidirectional ammeter. Usually tells you where you stand quite quckily
I have the same charger and have been trying to get my hands on a replacement relay. No luck in four months. Also there is a ceramic capacitor just to the right of the relay. Mine has popped and unable to read what it is. Any chance you had a schematic for this?? You have given me hope it can be fixed. Trying for fix for a good friend, so far been letting him down. Cheers and stay safe.
@@jeffescortlx Thanks for the info. I finally got my hands on a relay. Had it installed and still have the same problem, three led flashing. It is thinking something is wrong with the battery side, but not sure where to look next.
Do you know what senses the battery voltage and gives it the ok to turn on? Just double checked and no 33.8V, so it looks like the AC side isn't turning on.
Ok, looks good but! Three flashing lights and beeping noise = not charging, exactly how you started?? Unless I'm missing something 🙄 Usually three light's come on, then one flashes then two and finally 3 solid lights when charge complete. As I say 3 flashing and beeping = not charging/faulty, this is what the charger you 'repaired' is doing 🤔👍
The logic board is actually powered by the battery when you plug it in. It only senses the presence of AC power. The fuse is to protect the battery from shorting out through the charger. They aren't considered repairable because a new one ( $300-$400 ) is usually cheaper than repairing it. Between diagnosis, repair and down time its cheaper for most people to just swap out the chargers , and since JLG, SkyJack and Genie all use this charger it isnt hard to find one. And yes , its almost always the relay. People unplug the charger while its charging which draws a huge spark across the terminals , that relay normally doesn't open or close when its under load.
Thanks for the info. I think now that I understand it better after the repair it would be a reasonable $100 repair charge. Maybe some users would take the time to send one in for repair to keep one the self as a back up spare?
@@jeffescortlx I tried to talk my boss into rebuilding them because we buy 10 - 20 a year but in the end there wasn't enough of a price difference to be worth the trouble. (We repair aerial lifts) In this industry a rebuilt "anything" has to sell for roughly half the price of a new one, so we could only charge $200 , by the time you factor in acquiring "cores" ,labor and new parts we'd make less than the mark-up on a new one. They were designed to be throw aways , as an old industrial electrician it bugs the Hell out of me , but it's the world we live in now.
I used to repair this type of charger many time, and this output relay failure is very common. Absolutely correct that you need 24 volts battery to turn this charger on. That beeper means that the charger detect no battery connected. Great job..
Jeff, in your video you stopped at one point to say thats where the logic turns it on. That is where I am stuck. I am getting error of three flashing LEDs four times, which by the book indicates overcurrent state, and it will reset itself with no detriment to the charger. Mine is in a coninuous cycle of. I have changed batteries, checked wiring etc. The high voltage side is turning on for a split second, and then turning off. I have 24v at the relay connections from the battery, and the new relay is clicking on. Whether the new relay may be faulty I dont know, but doubt it. Any ideas where I should be looking? It can sense when no battery is connected, but for some reason is not seeing the 24v from the battery to say ok, charge. Thanks and stay safe
You can build a crude battery emulator using an electronic load which is diode isolated from a power supply. This way you don't risk damage to your power supply.
Hi. Any chance u or anyone reading this coment have part# or model of relay that was replaced. Also the resistor size which right in front of relay. Thanks.
I'd say about 90% of what I know is from experience. Started taking things apart at a young age. Eventually started putting things back together. I did go to a tech school, it helped me understand the math behind electronics, but it's mostly experience.
Mine charges for a little while, then after 30 minutes or so it beeps like 8 times, then shuts off and starts over again. any idea the issue? checked the batteries and each one shows 6.2v although I didn't disconnect them.
@@luke9511 I hear the double pump version of the Chinese one is better. For light duty every once in a while it's fine. But for someone like me that uses a eletronic desoldering pump daily hakko is the way to go.
Hello friend, with one here that when I call, it only beeps and flashes the three leds, I checked all the relays and found nothing and the output that goes to the battery is zero the tension that can be? would have a tip? only here from Brazil
I have seen battery chargers that use an output relay to stop reverse polarity connection and also no output is allowed if there is no battery voltage present. Also stops the assholes blowing the charger up by sparking the output leads. Very sneaky :-) Shame the protection relay bit the dust, likely not a cheap relay eather. So you are not changing the stepper motors... dam wrong device :)
Yep this one is well designed, lot's of protection steps. And it's not like the engineers did a bad job, it's rated for 30 amps but only see's 19. Maybe it was just a crummy relay.
Sounds nicely over rated :-D, perhaps the relay was a bit crap. When i've made a linear power supply for a frend i tend to go a bit overboard with the ratings of parts. Two pass transistors become three and a bigger heatsink, larger bridge rectifier and other bits. i just don't like the idea of boiling semiconductors. i'm a bit odd that way lol..
After doing some looking, this relay failure is common. I think the charger is smart enough to not turn on if the voltage is below a certain value, shorted or negative value. If it did connect reverse polarity with the charger engaged, I think the fuse would pop first.
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Love the change of pace, thanks for recording this!
Man I wish I had you next door !! :-) awesome repair & diagnosis !
That didnt fix the charger did it? Im curious if it worked when you charged it into a battery. If the battery ws too dead it would have had the 3 blinking lilghts.
Wow, very good repair! Excellent video. Totally different one. Love it. Hope to see more :)
Is the beeping and and all 3 green lights common during a charging cycle. I have the same problem and it won"t charge in that state.
A charge cycle is 1 light is lite at a time untill its fully charged. Thats how mine worked before it stopped charging.
Will you share were you get your relyas from without having to buy 30 at a time like most suppliers.
Thaanks for the video, the current thing sent me for a loop.
Its a pretty common industrial relay. Mouser, digi-key, Newark, Amazon or email should have them sold as 1 pc.
Yeah....I'm having the same problem you speak of . I don't think he fixed it. The blinking and beeping not normal. It's a reset.
I have that exact same charger in my scissor lift.
Thanks for the video.
After a few hard lessons with intelligent battery chargers I always use a flat battery on the output side with a bidirectional ammeter. Usually tells you where you stand quite quckily
very nice PSU
Well done!
I have the same charger and have been trying to get my hands on a replacement relay. No luck in four months. Also there is a ceramic capacitor just to the right of the relay. Mine has popped and unable to read what it is. Any chance you had a schematic for this?? You have given me hope it can be fixed. Trying for fix for a good friend, so far been letting him down. Cheers and stay safe.
HAT901ASDC12 should be compatible I believe.
@@jeffescortlx Thanks for the info. I finally got my hands on a relay. Had it installed and still have the same problem, three led flashing. It is thinking something is wrong with the battery side, but not sure where to look next.
Do you know what senses the battery voltage and gives it the ok to turn on? Just double checked and no 33.8V, so it looks like the AC side isn't turning on.
I should have said it starts to turn on and then turns off abruptly and starts the three LED flashing four times before reset
Ok, looks good but! Three flashing lights and beeping noise = not charging, exactly how you started??
Unless I'm missing something 🙄
Usually three light's come on, then one flashes then two and finally 3 solid lights when charge complete.
As I say 3 flashing and beeping = not charging/faulty, this is what the charger you 'repaired' is doing 🤔👍
Mine is encapsulated with epoxy .. is it a throw away ?
The logic board is actually powered by the battery when you plug it in.
It only senses the presence of AC power.
The fuse is to protect the battery from shorting out through the charger.
They aren't considered repairable because a new one ( $300-$400 ) is usually cheaper than repairing it.
Between diagnosis, repair and down time its cheaper for most people to just swap out the chargers , and since JLG, SkyJack and Genie all use this charger it isnt hard to find one.
And yes , its almost always the relay.
People unplug the charger while its charging which draws a huge spark across the terminals , that relay normally doesn't open or close when its under load.
Thanks for the info. I think now that I understand it better after the repair it would be a reasonable $100 repair charge. Maybe some users would take the time to send one in for repair to keep one the self as a back up spare?
@@jeffescortlx I tried to talk my boss into rebuilding them because we buy 10 - 20 a year but in the end there wasn't enough of a price difference to be worth the trouble.
(We repair aerial lifts)
In this industry a rebuilt "anything" has to sell for roughly half the price of a new one, so we could only charge $200 , by the time you factor in acquiring "cores" ,labor and new parts we'd make less than the mark-up on a new one.
They were designed to be throw aways , as an old industrial electrician it bugs the Hell out of me , but it's the world we live in now.
@@glennchartrand5411 I can understand that. Yes it's a bummer to see them get tossed out, they are built pretty well.
If you have 10 broken ones it certainly makes sense to fix them if all of them have the same problem (=the relay).
@@jeffescortlx I have one for repair, can you help me
I used to repair this type of charger many time, and this output relay failure is very common. Absolutely correct that you need 24 volts battery to turn this charger on. That beeper means that the charger detect no battery connected. Great job..
what if it turns on and charges for maybe 30 minutes, then starts over? It also gets really hot after a while.
@@grasscutter88 very likely caused by bad Mosfets, or the big diodes next to the HF transformer shorted, or dried capasitors (likely 1000uf 50 volt)..
Okay, well guess I'll just throw a new charger on it then. @@parmowaelo4229
Jeff, in your video you stopped at one point to say thats where the logic turns it on. That is where I am stuck. I am getting error of three flashing LEDs four times, which by the book indicates overcurrent state, and it will reset itself with no detriment to the charger. Mine is in a coninuous cycle of. I have changed batteries, checked wiring etc. The high voltage side is turning on for a split second, and then turning off. I have 24v at the relay connections from the battery, and the new relay is clicking on. Whether the new relay may be faulty I dont know, but doubt it. Any ideas where I should be looking? It can sense when no battery is connected, but for some reason is not seeing the 24v from the battery to say ok, charge. Thanks and stay safe
Sorry I'm not really sure where to start. I'm much better with trouble shooting things I'm not familiar with hands on.
Did you ever make any headway? I’ve got the same problem as you, overcurrent error.
@@samroesch none whatsoever. Put it in the too hard basket!
You can build a crude battery emulator using an electronic load which is diode isolated from a power supply. This way you don't risk damage to your power supply.
If its flashing and beeping 6 times means it's working? What is the meaning of 6 flashes?
Now I know why I’m a plumber
Hi. Any chance u or anyone reading this coment have part# or model of relay that was replaced. Also the resistor size which right in front of relay. Thanks.
Good job Jeff, where did you purchase the relay??
It's a very common relay, Digi-Key, Newark, Mouser, amazon or ebay should have them.
@@jeffescortlx would you have a part number for the relay?
Where do u learn this stuff. I can never find any good classes that n this stuff in my town
I'd say about 90% of what I know is from experience. Started taking things apart at a young age. Eventually started putting things back together. I did go to a tech school, it helped me understand the math behind electronics, but it's mostly experience.
Mine charges for a little while, then after 30 minutes or so it beeps like 8 times, then shuts off and starts over again. any idea the issue? checked the batteries and each one shows 6.2v although I didn't disconnect them.
Sorry I'm not familiar with the error codes on this one.
another awesome video! could i ask what is your thoughts on the cheapy desoldering iron you have on your desk next to your hakko?
If your going to use it more than once, I'd recommend saving up the difference and going with the Hakko.
@@jeffescortlx that bad huh? lol will do thanks!
@@luke9511 I hear the double pump version of the Chinese one is better. For light duty every once in a while it's fine. But for someone like me that uses a eletronic desoldering pump daily hakko is the way to go.
How replace the tire? gs 2632
Hey I have a broken charger can you fix it for me
You can guide me over the phone I’ll pay you
Estou com um de 24v, eleliga mais não consegui carregar.... o que devo reparar?
Hello friend, with one here that when I call, it only beeps and flashes the three leds, I checked all the relays and found nothing and the output that goes to the battery is zero the tension that can be? would have a tip? only here from Brazil
Sorry I'm not that familiar with this charger.
@@jeffescortlx ok
Great video 👍
E fica apitando... e recomeça várias vezes...
Diagram?
I didn't have/need one.
I have seen battery chargers that use an output relay to stop reverse polarity connection and also no output is allowed if there is no battery voltage present.
Also stops the assholes blowing the charger up by sparking the output leads.
Very sneaky :-)
Shame the protection relay bit the dust, likely not a cheap relay eather.
So you are not changing the stepper motors... dam wrong device :)
Yep this one is well designed, lot's of protection steps. And it's not like the engineers did a bad job, it's rated for 30 amps but only see's 19. Maybe it was just a crummy relay.
Sounds nicely over rated :-D, perhaps the relay was a bit crap.
When i've made a linear power supply for a frend i tend to go a bit overboard with the ratings of parts.
Two pass transistors become three and a bigger heatsink, larger bridge rectifier and other bits.
i just don't like the idea of boiling semiconductors.
i'm a bit odd that way lol..
they connected it backwards that is why it failed
After doing some looking, this relay failure is common. I think the charger is smart enough to not turn on if the voltage is below a certain value, shorted or negative value. If it did connect reverse polarity with the charger engaged, I think the fuse would pop first.
It's not fixed
Why not?
To my untrained eye these contacts looked good :(
To my trained eye too. The malfunction was the solder connection. The relay could have been salvaged but it is prudent is to replace it.