Hitachi Koki UC 36YRL User manual

PRODUCT NAME
Hitachi Charger
Model UC 36YRL
LIST No.
UC 36YRL: G884
Aug. 2007
International Sales Division
U
PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY --------------------------------------------------------- 1
1. Disassembly ----------------------------------------------------------------------------------------------------- 1
2. Reassembly ------------------------------------------------------------------------------------------------------ 1
3. Confirmation after Reassembly ----------------------------------------------------------------------------- 3
TROUBLESHOOTING GUIDE --------------------------------------------------------------------------------------------- 4
1. Troubleshooting Based on Pilot Lamp Indications ----------------------------------------------------- 4
2. Troubleshooting and Repair Procedures ----------------------------------------------------------------- 4
STANDARD REPAIR TIME (UNIT) SCHEDULES---------------------------------------------------------------------- 8
CONTENTS Page
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. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY
The [Bold] numbers in the descriptions below correspond to the item numbers in the Parts List and exploded
assembly diagram for the Model UC 36YRL .
-1. Disassembly
(1) Remove Case (A) [2] after removing the four Case Rubbers [12] and the four Tapping Screws (W/Flange) D3
x 18 [11] .
(2) Remove Fan [20] after removing the two Tapping Screws (W/Flange) D3 x 25 [19] and remove the connector
of the Fan [20] from the Printed Circuit Board Ass'y [7].
(3) Remove Fin (D) [5] and Fin (E) [8] from the Printed Circuit Board Ass'y [7] after removing the three Machine
Screws (W/Washers) M3 x 12 [3], three Nuts M3 [6] and four TP Tapping Screws D3 x 8 [4].
(4) Remove the Insulator [9] from the Printed Circuit Board Ass'y [7].
(5) Remove the Terminal Holder [15] after removing the three TP Tapping Screws D3 x 8 [4], connector of the
Terminal Holder [15] from the Printed Circuit Board Ass'y [7] and melt their soldered connections of the red
and black lead wires of the Terminal Holder [15] with a soldering iron and remove them.
(6) Remove the Cord [18] from the Printed Circuit Board Ass'y [7] after melting their soldered connections with a
soldering iron. (The long lead wire of the Cord [18] for U.S.A/Canada is covered with the tube.)
(7) A Prism [14] for pilot lamps is built into Case (A) [2] and the Filter [16] is sticked on Case (A) [2].
(NOTE)
Ideally, the soldered portions should be freed with a solder absorber. If a soldering iron must be used,
use one with a rated power of 35 W.
As excessive heat may damage the material of the printed circuit board, use of the soldering iron should be
limited to less than three seconds at one time.
-2. Reassembly
Reassembly can be accomplished by following the disassembly procedures in reverse; however, special attention
should be given to ensure that lamps, cord armor and charging terminals are properly installed in their prescribed
grooves.
(1) Screw tightening torque
1 Machine Screws (W/Washers) M3 x 12 [3] ................................................... 0.6 - 1.0 N•m (6.0 - 10.0 kgf•cm)
2 TP Tapping Screw D3 x 8 [4]
• Attaching Fin (D) [5] and Fin (E) [8] ........................................................... 0.8 - 1.2 N•m (8.0 - 12.0 kgf•cm)
• Attaching Terminal Holder [15] ................................................................... 0.3 - 0.7 N•m (3.0 - 7.0 kgf•cm)
3 Tapping Screw (W/Flange) D3 x 18 [11] ....................................................... 0.8 - 1.2 N•m (8.0 - 12.0 kgf•cm)
4 Tapping Screw (W/Flange) D3 x 25 [19] ....................................................... 0.8 - 1.2 N•m (8.0 - 12.0 kgf•cm)
--
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Fig. 1
Case (B) [10]
Machine Screw (W/Washers)
M3 x 12 [3]
Prism [14]
Case (A) [2]
Printed Circuit Board Ass'y [7]
Insulator [9]
Fin (E) [8]
Filter [16]
Terminal Holder [15]
Nut M3 [6]
Fin (D) [5]
Fan [20]
Cord [18]
TP Tapping Screw D3 x 8 [4]
TP Tapping Screw D3 x 8 [4]
Connector of the Terminal Holder [15]
Lead wire (red) of the
Terminal Holder [15]
Connector of the Fan [20]
Lead wire (black) of the
Terminal Holder [15]
Fuse [17]
Long lead wire of the Cord [18]
Tube (for U.S.A/Canada)
Tapping Screw (W/Flange) D3 x 25 [19]
Short lead wire of the Cord [18]
--
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-3. Confirmation after Reassembly
(1) Confirm the following after reassembly. The red pilot lamp on the charger lights up when charging is started.
• When charging an BSL 3626 battery, confirm that the red pilot lamp flashes at 1 second intervals approx.
80 minutes from commencing charging.
(2) Measure the insulation resistance and conduct a dielectric strength test.
• Insulation resistance: 10 M Ωor more between the plug blade of cord and the name plate or case fastening
screws, with a DC 500 V megohm tester.
• Dielectric strength test:
(a) Between the plug blade of the cord and the charging terminal blade.
(b) Between the plug blade of the cord and the name plate or the fastening screws on the case.
Based on the voltage listed on the Name Plate, dielectric strength test should be conducted.
CAUTION: Without fail, insulation resistance must be measured between the plug blade of the cord and
the name plate or the fastening screws, and dielectric strength test must be conducted
between the plug blade of the cord and the charging terminal blade or between the plug blade
of the cord and the name plate or the fastening screws on the case. Under no circumstances
should testing be conducted between both blades of the plug, or both blades of the charging
terminal, which may cause burn-out of the charger.
Voltage on the name plate Test voltage
120 V
220 V to 240 V
AC 1,240 V (1 minute)
AC 3,750 V (1 minute)
--
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. TROUBLESHOOTING GUIDE
-1. Troubleshooting Based on Pilot Lamp Indications
Phenomenon
Pilot lamp fails to light or flash.
Red pilot lamp does not stay lit
(continues to flicker) after
battery has been connected.
Pilot lamp remains green (red
fails to light) after battery has
been connected.
Pilot lamp indicates abnormality
by flashing red rapidly (at 0.2
second intervals.)
(1) Faulty AC cord
(2) Blown fuse (3.15 A) on primary side
(1) Poor connection of (T) or (LS) terminal
(2) Faulty battery (open circuit)
(3) Faulty PCB
(1) Poor connection of (T) or (LS) terminal
(2) Faulty PCB
(1) Faulty battery (short-circuit, or open circuit)
(2) Faulty PCB
Typical causes
Refer to trouble mode (A).
Check procedures
Refer to trouble mode (B).
Refer to trouble mode (C).
Refer to trouble mode (D).
NO
NO
NO
NO
YES
YES
YES
YES
Pilot lamp fails to light or flash.
Apply rated voltage.
Is rated
voltage applied
to the plug ?
Is there
continuity between
the blades of the
AC cord plug ?
Is there
an open circuit in
the AC cord ?
Is the fuse
on the primary side
blown ?
Replace PCB.
Faulty internal circuit
Replace PCB.
Replace the AC cord.
Faulty internal circuit
Check with tester.
Replace the fuse.
-2. Troubleshooting and Repair Procedures
(1) Trouble mode (A)
--
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