Lester 19300 User manual

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OWNERS MANUAL
BATTERY CHARGER
MODEL 19300
Specifications
AC Input: 108-125 Volts AC, 60 Hertz, single-phase, 10.5 amps
DC Output: 36 Volts DC, 21 amps tapering to 6 @ 45 VDC
Connections: 9 1/4 ft. DC cord with Power Wise plug, Option -98 (602718)
17 ft. DC cord with Power Wise plug, Option -18 (602719)
9 ¼ ft. DC cord with Anderson SB 50 gray connector, Option -03 (602715)
6 ft. DC cord with ring terminal & QD ignition enable, Option -23 (602714)
6 ft. min. / 7 ¾ ft. max. AC cord with grounded 3-prong plug
Dimensions: 8-15/16H X 7-13/16W X 10-5/8D
Mounting: Set on shelf, wall mount with keyholes, or hang from ceiling securely
Weight: 31 lbs.
PLEASE SAVE THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS
For correct operation of this charger, it is important to read and be familiar
with this entire manual before installing and operating the charger.
DO NOT DISCARD THIS MANUAL AFTER READING.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:
BECOME ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE
SAFETY INSTRUCTIONS, PERSONAL INJURY OR PROPERTY DAMAGE CAN OCCUR.
INTRODUCTION
This battery charger is designed to recharge deep-
cycle, wet lead-acid batteries. A ferroresonant
transformer is used to provide a highly reliable, AC
line voltage compensating unit with a minimum of
moving parts, designed for long, trouble-free service.
An electronic charge controller turns the charger on
and off automatically. This controller determines full
charge of the batteries by measuring the rate at
which the battery voltage increases. When the
battery is fully charged, the charger turns off.
INITIAL INSTALLATION
The AC line to which the charger is to be connected
must be capable of supplying 10 amperes to this
charger.
CAUTION: TO REDUCE THE RISK OF FIRE,
USE THIS CHARGER ONLY ON CIRCUITS
PROVIDED WITH A MAXIMUM OF 20 AMPERE
BRANCH CIRCUIT PROTECTION (CIRCUIT
BREAKER OR FUSE), IN ACCORDANCE WITH
THE NATIONAL ELECTRICAL CODE, ANSI/NFPA
70, AND ALL LOCAL CODES AND ORDINANCES.
The use of an extension cord with the charger
should be avoided. The use of an improper
extension cord could result in a risk of a fire or
electric shock. If an extension cord must be used,
use a three-conductor, No. 14 AWG cord with
ground, properly wired, in good electrical condition
and keep it as short as possible. Make sure that the
pins on the plug of the extension cord are the same
number, size, and shape as that of the plug on the
battery charger. Locate all cords so that they will not
be stepped on, tripped over, or otherwise subjected
to damage or stress.
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Do not operate this charger if it has received a sharp
blow, was dropped or otherwise damaged in any
manner; refer to a qualified service agent.
Provide adequate ventilation for the batteries and
charger. The convection-cooled design requires an
unobstructed flow of cooling air for proper operation.
Keep all charger ventilation openings at least two
inches (2") (5cm) away from walls and other objects.
Do not allow clothing, blankets, or other material to
cover the charger. Do not block cooling vents.
WARNING: CHARGERS CAN IGNITE
FLAMMABLE MATERIALS AND VAPORS. DO
NOT USE NEAR FUELS, GRAIN DUST,
SOLVENTS, OR OTHER FLAMMABLES.
WARNING: TO REDUCE THE RISK OF AN
ELECTRIC SHOCK, KEEP THE CHARGER DRY.
DO NOT EXPOSE IT TO RAIN, SNOW OR
LIQUIDS. FOR STORAGE, KEEP THE CHARGER
IN A BUILDING.
ATTENTION! Ne pas exposer a la pluie.
GROUNDING INSTRUCTIONS
This battery charger must be grounded to reduce the
risk of electric shock. This charger is equipped with
an electric cord having an equipment-grounding
conductor. Chargers designed for a nominal 120
volts, 60 Hertz come equipped with a grounding type
plug as well. This plug must be connected to an
appropriate receptacle that is properly installed and
grounded in accordance with the National Electrical
Code and all local codes and ordinances.
WARNING: IMPROPER CONNECTION OF
THE EQUIPMENT-GROUNDING CONDUCTOR
CAN RESULT IN A RISK OF AN ELECTRIC
SHOCK.
The conductor with insulation having an outer
surface that is green, with or without yellow stripe(s),
is the equipment-grounding conductor. If repair or
replacement of the electric cord or plug is necessary,
do not connect the equipment-grounding connector
to a live terminal. Refer to a qualified service agent.
Battery chargers equipped with a grounding plug as
illustrated in Figure A are for use on a nominal 120
volt circuit. A temporary adapter, as illustrated in
Figures B and C, may be used to connect this plug
to a two-pole receptacle as shown in Figure C if a
properly grounded outlet is not available. The
temporary adapter should be used only until a
properly grounded outlet can be installed by a
qualified electrician. The green-colored rigid ear or
lug extending from the adapter must be connected
to a permanent ground such as a properly grounded
outlet box.
GROUNDING METHODS
ABC
CONNECTED
TO COVER
OF GROUNDED
OUTLET BOX
ADAPTER
COVER OF
GROUNDED
OUTLET BOX
GROUNDING
BLADE GROUNDED
OUTLET
GROUNDING
MEANS
NOTE: The use of the adapter shown in Figures B
and C is not permitted in Canada.
NORMAL OPERATION
The instructions printed on the charger are for
daily reference.
With the charger DC output plug disconnected from
the vehicle, connect the AC power supply cord to a
120 Volt, 60 Hertz outlet.
WARNING: TO REDUCE THE RISK OF AN
ELECTRIC SHOCK, CONNECT ONLY TO A
PROPERLY GROUNDED, SINGLE-PHASE
(3-WIRE) OUTLET. REFER TO GROUNDING
INSTRUCTIONS.
CAUTION: MAKE SURE THE BATTERY
PACK IS A 36 VOLT, 18 CELL, SERIES
CONNECTED WET LEAD-ACID SYSTEM WITH A
CAPACITY OF 180 TO 245 AMPERE-HOURS (20
HR. RATE). OTHER TYPES OF BATTERIES MAY
BURST CAUSING PERSONAL INJURY AND
DAMAGE.
ATTENTION! Utiliser pour charger
uniquement les accumulateurs au plomb à
electrolyte liquide. D'autres types d'accumu-
lateurs pourraient éclater et causer des
blessures ou domages.
DANGER: RISK OF ELECTRIC SHOCK! DO
NOT TOUCH UNINSULATED PORTION OF
CHARGER/VEHICLE OUTPUT CONNECTION OR
BATTERY TERMINALS.
DANGER: Risque de chocks électriques. Ne
pas toucher les parties non isolées du
connecteur de sorti ou les bornes non isolées de
l'accumulateur.
DANGER: VISUALLY AND MANUALLY
INSPECT TO VERIFY THAT THE DC OUTPUT
CORD, PLUG AND BATTERY CHARGING
RECEPTACLE ARE IN GOOD WORKING
CONDITION BEFORE EACH AND EVERY USE
AND DO NOT USE THE CHARGER IF:

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•The DC charging receptacle does not grip the
DC output plug tightly, is loose or does not make
a good electrical connection.
•The DC output plug and/or charging receptacle
feel hotter than normal.
•The DC output plug pins or receptacle contacts
are bent, corroded or are dark or bluish in
appearance.
•The DC output plug, cords, receptacle or vehicle
charging wiring are cut, worn, broken, or have
any exposed conductors.
•The DC output plug, cords, charger or
receptacles are damaged or distressed in any
way.
Using the charger with any of the above symptoms
could result in a fire, property damage, or personal
injury.
Have your distributor, dealer or other qualified
service agent repair or replace worn or damaged
parts immediately. Repairs should not be attempted
by people who are not qualified.
1. Insert the DC output plug completely into the
matching vehicle receptacle by grasping the
plug handle and pushing the plug straight into
the receptacle.
2. Charger will start automatically three to five (3-5)
seconds after plug insertion.
DANGER: USE IN WELL VENTILATED
AREA. ELECTRICAL ARCING COULD IGNITE
HYDROGEN GAS PRODUCED BY THE BATTERY
WHILE CHARGING. KEEP SPARKS, OPEN
FLAME AND SMOKING MATERIALS AWAY
FROM BATTERIES. NEVER DISCONNECT OR
CONNECT DC PLUG FROM VEHICLE UNLESS
CERTAIN THAT THE CHARGER IS OFF. TO
INTERRUPT CHARGE CYCLE, DISCONNECT AC
PLUG FROM OUTLET BEFORE REMOVING DC
PLUG FROM VEHICLE RECEPTACLE.
Monitor the ammeter for the correct charge rate.
The initial charge rate will vary from 16 to 25
amperes, depending upon the condition of the
batteries and how much the batteries have been
discharged.
Slight variations in the initial charge rate may
also result from AC input line voltages which are
higher or lower than nominal. Higher line
voltages increase the initial charge rate while
lower line voltages reduce the charge rate.
If the batteries are heavily discharged and the
AC input line voltage is higher than nominal, the
initial charge rate may exceed 25 amperes.
Under normal conditions the charge rate will
taper to less than 25 amperes within 30 minutes.
If the ammeter still reads 25 amperes or more
after 30 minutes, turn the charger off by
disconnecting the AC plug from its outlet.
CAUTION: TO PREVENT BATTERY
DAMAGE, CHARGER OVERHEATING, AND
TRANSFORMER BURNOUT, DO NOT ALLOW
THE CHARGER TO OPERATE FOR MORE THAN
30 MINUTES WITH THE AMMETER READING IN
EXCESS OF 25 AMPS. THIS IS MISUSE AND
WILL CAUSE OVERHEATING AND TRANS-
FORMER BURNOUT.
During charge, the battery voltage increases
gradually which causes the charge rate to
decrease. Good battery cells should each rise
to approximately 2.5 volts DC which will allow
the charge rate to taper to less than 6 amps.
Since each cell accepts charge at a slightly
different rate, normal charging with the ammeter
reading in the 4 to 8 amps area for the last few
hours of charge is important to achieve
equalization of all battery cells every time the
batteries are charged.
As batteries age, individual cells weaken
resulting in lower than normal finish charge
voltage. As the finish charge voltage decreases,
the charge rate will no longer decrease and
taper into the 4 to 8 amps range on the
ammeter. The electronic charge controller will,
however, still determine when the batteries have
reached full charge and turn the charger off.
Even though they are properly charged, older
batteries will gradually lose capacity, and should
be replaced when they will no longer perform as
required.
3. Charger will automatically stop when batteries
are fully charged. Charge time will vary with
battery capacity, depth of discharge,
temperature and age. Allow 10 to 12 hours for
normal charging. Batteries that are heavily
discharged, new batteries, or batteries charged
in cool temperatures require more time. The
electronic charge controller will turn charger off
after 16 hours regardless of battery state of
charge.
4. To stop charger during the charge cycle,
disconnect AC plug from outlet before
disconnecting DC plug from vehicle receptacle.
After charger is off, remove DC plug by grasping
plug handle and pulling plug directly out of
receptacle.
WARNING: TO AVOID DAMAGE TO THE
CHARGER CORD, PLUG, AND BATTERY
RECEPTACLE, DO NOT PULL ON THE
CHARGER CORD. DO NOT TWIST, ROCK, OR
PULL THE PLUG SIDEWAYS.

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BATTERY STORAGE MAINTENANCE
During vehicle storage the charger may be left
connected to the batteries. Charger will turn on
periodically to keep batteries charged. Be sure
charger is connected to a live AC power outlet. If
AC power is turned off during storage periods, do
not leave charger DC output plug connected to
vehicle receptacle.
PROPER CARE OF DEEP CYCLE MOTIVE
POWER BATTERIES
Motive power batteries are subjected to severe
deep-cycle duty on a daily basis. Although these
batteries are designed to withstand such duty, the
following precautions must be observed to obtain
good performance and maximum cycle life:
CAUTION: ALWAYS WEAR PROTECTIVE
EYE SHIELDS AND CLOTHING WHEN WORKING
WITH BATTERIES. BATTERIES CONTAIN ACIDS
WHICH CAN CAUSE BODILY HARM. DO NOT
PUT WRENCHES OR OTHER METAL OBJECTS
ACROSS THE BATTERY TERMINAL OR
BATTERY TOP. ARCING OR EXPLOSION OF
THE BATTERY CAN RESULT.
1. When installing new batteries, be sure the
polarity of each battery and overall battery pack
is correct. Due to the electrical characteristics of
this charger, it is possible to hook up the
batteries improperly and not blow the fuse when
charging. Battery and/or charger damage can
result.
2. New batteries should be given a full charge
before their first use because it is difficult to
know how long the batteries have been stored.
3. Limit the use of new batteries for the first 20
cycles. New batteries and older batteries that
have been in storage are not capable of their
rated output until they have been discharged
and charged a number of times.
4. DO NOT EXCESSIVELY DISCHARGE THE
BATTERIES. Excessive discharge can cause
polarity reversal of individual cells resulting in
complete failure shortly thereafter. Heavily
discharging (over 60%) new batteries before
they have been broken in (approximately 20
cycles) can cause permanent cell damage,
resulting in reduced energy capacity and
shortened life.
5. Maintain the proper electrolyte level by adding
water when necessary. Distilled or deionized
water is free of contaminants and preferred for
this use. Never allow the electrolyte level to fall
below the top of the battery plates. Electrolyte
levels lower during discharge and rise during
charge. Therefore, to prevent the overflow of
electrolyte when charging, it is mandatory that
water be added to cells AFTER they have been
fully charged; do not overfill. Old batteries
require more frequent additions of water than do
new batteries.
6. Hard crystalline sulfates form when batteries in
storage are not maintained in a charged active
state. Internal self-discharge can bring about
the start of this condition in as little as three days
in warm temperatures. Batteries allowed to sit
unmaintained in storage will self-discharge,
sulfate to various degrees and lose capacity.
Repeated charging without using the batteries
between charges can recover some of the lost
power, range, and life, but some permanent loss
should be expected.
7. When the temperature falls below 65°F, the
batteries should be placed on charge as soon
after use as possible. Cold batteries require
more time to fully recharge.
8. The tops of the batteries and battery hold-downs
must be kept clean and dry at all times to
prevent excessive self-discharge and flow of
current between the battery posts and frame.
Electrolyte spilled on the batteries never dries or
evaporates.
9. All connections to batteries that are bolted must
be maintained clean and tight. Due to heating
and vibration, bolted connections may loosen
over time. Re-tighten the connections twice
yearly to the manufacturer's specified torque.
10. Follow all operating instructions, cautions, and
warnings as specified in this manual, on the
charger, and in your vehicle owner’s manual.
TROUBLESHOOTING GUIDE
To be able to troubleshoot safely and effectively,
it is important to read this guide completely
before beginning any tests.
CAUTION: DO NOT DISASSEMBLE THE
CHARGER. TAKE IT TO A QUALIFIED SERVICE
AGENT WHEN SERVICE OR REPAIR IS
REQUIRED. INCORRECT REASSEMBLY MAY
RESULT IN A RISK OF ELECTRIC SHOCK OR
FIRE. THE FOLLOWING PROCEDURES ARE
INTENDED ONLY TO DETERMINE IF A
MALFUNCTION MAY EXIST IN THE CHARGER.
DANGER: TO REDUCE THE RISK OF
ELECTRIC SHOCK, ALWAYS DISCONNECT
BOTH THE AC POWER PLUG AND THE DC
OUTPUT PLUG BEFORE ATTEMPTING ANY
MAINTENANCE OR CLEANING.

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WARNING: DO NOT OPERATE THE
CHARGER IF IT IS MALFUNCTIONING.
PERSONAL INJURY OR PROPERTY DAMAGE
COULD RESULT.
To determine if a charger malfunction exists, identify
the problem from the following list and refer to the
appropriate section for detailed instructions.
1. CHARGER DOES NOT TURN ON
2. CHARGER FUSE BLOWS
3. THE AMMETER NEEDLE REMAINS AT 25
AMPS OR HIGHER FOR MORE THAN ONE-
HALF (½) HOUR
4. CHARGER DOES NOT TURN OFF
5. THE BUILDING AC LINE CIRCUIT BREAKER
OR FUSE BLOWS
If the problem is other than listed above, refer to a
qualified service agent for additional troubleshooting
procedures.
1. CHARGER DOES NOT TURN ON
The DC plug must be disconnected and reconnected
to start the charger after turn off.
Connect the power supply cord securely to a live AC
outlet. Visually inspect the DC output plug and
battery receptacle to be sure they are in good
working condition.
WARNING: IF THE PLUG OR RECEPTACLE
IS BROKEN, TWISTED, BENT OR LOOSE AND
DOES NOT MAKE GOOD ELECTRICAL
CONTACT, HAVE IT REPLACED BY A
QUALIFIED SERVICE AGENT IMMEDIATELY. DO
NOT USE THIS CHARGER IN THIS CONDITION
AS FIRE OR PERSONAL INJURY CAN RESULT.
If the plug and receptacle are good, connect the DC
plug into the receptacle and listen for the power
relay inside the charger to "click" on within five
seconds. If the "click" is not heard remove the DC
plug from the receptacle and connect the DC plug of
another charger, which you know is operating
properly, to the receptacle.
If still no "click" is heard, a malfunction in the
batteries or receptacle wiring exists. If the "click" is
heard, the batteries and receptacle are good, and a
malfunction exists in the original charger.
If the relay "click" is heard, a hum from the
transformer should be heard and the ammeter
should indicate the charge rate. If no transformer
hum is heard, check to be sure the AC power supply
cord is securely connected to a live AC outlet.
When three-prong to two-prong adapters are used,
they tend to work loose, resulting in a poor
connection. Check the AC line fuse or circuit
breaker and, if possible, connect a functioning
charger, utility light, or other electrical appliance to
the outlet to verify the presence of AC power. If AC
power is present, and still no transformer hum is
heard, the charger is malfunctioning. If the relay
"clicks" and the transformer hums, but no charge
rate is indicated on the ammeter, the charger is
malfunctioning.
2. CHARGER FUSE BLOWS
The charger fuse assembly consists of a double
ended fuse wire visible through a transparent cover
mounted on the front panel. Each half of the fuse
wire serves as an individual fuse link which protects
the charger in the event one or both rectifier diodes
fail, or a reverse polarity connection is made to the
batteries.
Check the fuse assembly visually for an open or
blown fuse link. If both half links of the fuse
assembly blow as soon as the DC output plug is
connected to the battery receptacle, the polarity of
the batteries may be reversed. If no battery or
receptacle maintenance has been performed prior to
the fuse blowing, the charger is malfunctioning. If
only one half link blows the charge rate will be low
and the charger is malfunctioning.
CAUTION: DO NOT USE THE CHARGER IF
THE OUTPUT IS LOW. BATTERIES WILL NOT
REACH FULL CHARGE, THEREBY INCREASING
THE POSSIBILITY OF A HARMFUL DEEP
DISCHARGE DURING THEIR NEXT USE.
3. AMMETER NEEDLE REMAINS AT 25 AMPS
OR HIGHER FOR MORE THAN ONE-HALF
(½) HOUR
This high charge rate is caused by misuse. The
charger is connected to a battery pack with a system
voltage lower than or amp-hour capacity greater
than specified on the charger. If connected to a 12,
18, 24, 30, 32 or other battery system less than 36
volts, the charge rate will not taper and decrease to
25 amps or less within 30 minutes. If battery
maintenance has recently been performed, a
possible error is to install one or more of the 6 volt
batteries in the battery pack in reverse polarity.
Have a qualified service agent inspect the battery
connections and test the system voltage with a
suitable voltmeter.
4. THE CHARGER DOES NOT TURN OFF
New batteries or batteries charged in cold
temperatures may require an extended charge time
to achieve full charge. However, if the charger runs
for more than 16 hours without shutting off, the
charger is malfunctioning.

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5. THE BUILDING AC LINE CIRCUIT BREAKER
OR FUSE BLOWS
This condition can be caused by a charger problem,
a "weak" fuse or circuit breaker protecting the circuit,
or an overloaded circuit. If the building AC power
fuse or circuit breaker blows, connect the charger to
other outlets (on different circuits) in the building. If
the charger operates properly on other circuits, have
a qualified electrician inspect and test the original
circuit. If the charger causes other fuses or circuit
breakers (in the building) to blow, the charger should
be tested by a qualified service agent.
WIRING DIAGRAM
MODEL 19300

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PARTS LIST FOR CHARGER
Model 19300
E-Z-GO
REF. No. PART NO. QTY. DESCRIPTION
1 603192 1
CASE ASSEMBLY, OPTION -98 (602718), -18 (602719), -03 (602715)
1 604094 1 CASE ASSEMBLY, OPTION -23 (602714)
2 603193 1 TRANSFORMER ASSEMBLY
3 603207 1 FUSE ASSEMBLY
4 603208 1
DIODE RECTIFIER ASSEMBLY
5 603194 1
ELECTRONIC CHARGE CONTROLLER (INCLUDES RELAY BOARD #10),
OPTION -98 (602718), -18 (602719), -03 (602715)
5 604091 1
ELECTRONIC CHARGE CONTROLLER (INCLUDES RELAY BOARD #12),
OPTION -23 (602714)
6 603195 1 DC CORDSET, 12/2 & 16/1, 120” POWER WISE PLUG, OPTION-98 (602718)
6 603843 1
DC CORDSET, 12/2 & 16/1, 216” POWER WISE PLUG, OPTION-18 (602719)
6 603844 1
DC CORDSET, 12/2, 133” SB50 GRAY, OPTION –03 (602715)
6 604093 1
DC CORDSET, 12/2 & 16/1, 72” W/ 5/16 RING TERM. & ¼ QD, OPTION -23
(602714)
7 603196 1
AC CORDSET, 16/3, 97” W/BUSHING & NEMA 5-15P
8 603209 1
AMMETER, 30 AMP
9 603210 1
CAPACITOR, 3 MFD, 660 VAC
10 603197 1
RELAY BOARD ASSEMBLY, OPTION -98 (602718), -18 (602719), -03 (602715)
10 604092 1
RELAY BOARD ASSEMBLY, OPTION -23 (602714)
11 604124 1 RELAY KIT, DC SENCE DISCONNECT, OPTION -23 (602714)
12 22009G1 4 BUMPER, RUBBER, OPTION -23 (602714)