If the LBC is still not working after the initial steps and inspection, check for circuitry and circuit board failure. Using the KIM LAUBE & CO., INC Deluxe Battery Charger Tester, you should receive a reading of 9-13 DC volts and .9-1.5 DC amps. Check the Charger cut out. If the LBC is still charging or the LED is still on, then the relay needs to be replaced (part # 5430030000). If you recieve a proper reading from the LBC Tester but the LED is not on, replace the LED (part # 5400090000). If you are getting the proper readings then proceed with the following steps.
ALWAYS UNPLUG THE UNIT BEFORE OPENING! Open the LBC Housing and inspect it for burns or discoloration on the Circuit Board and LBC on the opposite side of the Connectors. PLEASE NOTE: Identify which Circuit Board has been installed in the Charger, the TAN & GREEN or the GREEN & GREEN. If you are working with the TAN & GREEN Circuit Board then follow these steps accordingly and use "DIAGRAM 3LBC" & the "5LBC CHARGER CIRCUIT BOARD DIAGRAM." If you are working on the REV-2 Circuit Board (Green & Green), follow the same steps accordingly using "DIAGRAM 4LBC" and the "6LBC CHARGER CIRCUIT BOARD DIAGRAM." Set the volt meter to OHMS and place both of the terminals onto the electrical plug of the LBC, one on each prong. A 110v LBC should read approximatly 47 ohms. A 220v LBC should read 182 ohms. If you are not getting any reading, check for an open circuit in the cord or plug. Also inspect the Circuit Board for cracks or damage. Next, place the meter terminals onto # 1 and # 4 of the Transformer connections (test the points on "A" AND "B" on DIAGRAM 3LBC or 4LBC) and you should get a reading of 47 ohms for a 110v Circuit Board and 182 ohms for a 240v Circuit Board. If the reading is not within +/- 10 % then replace the Transformer (part # 5430090000)
Make sure that the unit is still UNPLUGGED from the AC power source. Set the volt meter to continuity, place the meter terminals on the Circuit Breaker leads and test points "D" and "E" (see DIAGRAM 3LBC or DIAGRAM 4LBC) If you are not receiving any continuity, replace the Circuit Breaker (part # 5400100000).
With the Charger UNPLUGGED from a power source, place the meter, set on ohms, on the green switch leads or on test points "J" and "K" (see DIAGRAM 3LBC or DIAGRAM 4LBC). Making sure that you have a good contact with solder, depress the switch and keep holding it. The meter should start reading about .5 ohms to .3 ohms and go down to .0 ohms. This is indicating continuity. Keeping the meter terminals on test points "J" and "K" let go of the start switch. The ohm meter should move back up to 3.0 ohms to 5.0 ohms. If the switch does not respond to this, replace it (part # 5400080000).
Do not allow the LBC switch to be pressed down, causing current to flow to the rest of the Circuit Board. Also make sure that nothing at all is in the Battery Cradle. Carefully plug the LBC into an appropriate AC power source. CAUTION!!! DEADLY VOLTAGE LEVELS ARE PRESENT ON THE CIRCUIT BOARD AND POWER CORD WHEN IT IS PLUGGED IN. DO NOT WORK ON A METAL TABLE OR ANY OTHER SURFACE THAT IS CONDUCTIVE. KEEP YOUR FINGERS AND TOOLS AWAY FROM THE AC LINE LEVEL SIDE OF THE CIRCUIT BOARD. THIS AREA IS MARKED DANGER ON DIAGRAM 3LBC AND DIAGRAM 4LBC. THIS WILL CAUSE A FULL CURRENT FLOW AND A POSSIBLY HARMFUL ELECTRICAL SHOCK TO YOU!
Place the meter on AC voltage (VAC). Measure between pins # 5 and #8 of the Transformer (test points "C" and "D" on DIAGRAM 3LBC or DIAGRAM 4LBC) with the meter. The reading should be approximately 16.5 v AC. If you do not get this reading, replace the Transformer. Now set the meter to DC volts (VDC) and measure across the outside leads of the Bridge Rectifier or test points "G" and "H" (NOTE: place the Black lead of the meter on test point "G" and the red lead on test point "H"). You should read approximately 15 DC volts. If AC voltage is at the Bridge Rectifier but the DC voltage is not correct, replace the Bridge Rectifier (part # 5430020000). Using the VDC setting on the meter, measure from test point "G" (black lead) and test point "F" (red lead). You should receive a reading of 15 DC volts. If this reading is not present, then replace Diode #1 and Diode #2 (part # 5430040000). If you can't find the exact source of the problem, then you might choose to replace the complete Circuit Board Assembly (refer to the parts list). Or you can call our Technical Support Line (805) 240-1313.