24v Battery Charger Repair 

Love the change of pace, thanks for recording this!

Man I wish I had you next door !! :-) awesome repair & diagnosis !

Wow, very good repair! Excellent video. Totally different one. Love it. Hope to see more :)

I have that exact same charger in my scissor lift. Thanks for the video.

Now I know why I’m a plumber

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.

Well done!

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 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..

very nice PSU

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

Great video 👍

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.

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.

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.

Mine is encapsulated with epoxy .. is it a throw away ?

How replace the tire? gs 2632

If its flashing and beeping 6 times means it's working? What is the meaning of 6 flashes?

Estou com um de 24v, eleliga mais não consegui carregar.... o que devo reparar?

Hey I have a broken charger can you fix it for me

Where do u learn this stuff. I can never find any good classes that n this stuff in my town

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.

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

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.

Good job Jeff, where did you purchase the relay??

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

another awesome video! could i ask what is your thoughts on the cheapy desoldering iron you have on your desk next to your hakko?

Diagram?

E fica apitando... e recomeça várias vezes...

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 :)

It's not fixed

they connected it backwards that is why it failed

To my untrained eye these contacts looked good :(