TO INFORM YOU
PRODUCT
SUPPORT
BULLETIN # 474
TO:
DATE: January 2008
AUTHORIZED portable electric tool SERVICE STATIONS
factory SERVICE / SALES SUPPORT BRANCH
TOOL(S) \ PRODUCT(S) AFFECTED: 2601-20 18.0V Li-Ion Compact Driver/Drill
48-11-1815 18.0V 1.4Ahr Li-Ion Battery Pack, 48-59-1801 18.0V Charger
SUBJECT: Troubleshooting Guide 48-59-1801 18.0V Charger / 48-11-1815 18.0V Li-Ion Battery Pack
Symptom
Battery Pack
connected to
Charger, RED
or GREEN
LED lights
failure to turn
“on”.
Possible Cause(s)
Solution(s)
Line voltage too high or too
low (or no power present)
Remove Battery Pack. Unplug Charger and verify correct line voltage 90VAC – 132VAC for 120VAC Charger
Charger temperature too high
>212ºF (100ºC)
Allow Charger to cool 3-5 minutes before attempting charge. Power must be
removed for a minimum of one minute then reapplied if this condition occurs.
Faulty Battery Pack – ‘blown’
FET
Try known good Battery Pack on the questionable Charger, or try questionable
Battery Pack on known good Charger. FET can fail when battery pack is
repeatedly over-loaded - under extreme circumstances, the internal
temperature of the battery becomes too high or subjected to water.
Faulty Charger
UNPLUG Charger - high voltage is present at the AC High Voltage Heat Sink when AC line voltage is applied to the Charger circuit board. Check for ‘blown’
Charger DC low voltage ‘one-time’ output protection fuse F2 with Volt-Ohm
Meter and/or ‘blown’ Charger AC line fuse - F1, if fuse F2 checks OK. NOTE:
Before checking fuses F1 or F2 unplug the Charger from power source and let
it sit for 3-4 minutes before disassembling – this allows circuit board capacitor
to self discharge.
DC HEAT SINK SIDE
F2 FUSE
F1 FUSE
Use only a battery operated VOM to perform FUSE continuity test – it may be
necessary to pierce / scrap the protective coating of PCB board on end of fuse
to obtain valid continuity reading.
AC HIGH VOLTAGE HEAT SINK
48-59-1801 Charger has no serviceable replacement
parts.
MILWAUKEE ELECTRIC TOOL CORPORATION
13135 WEST LISBON ROAD • BROOKFIELD, WISCONSIN 53005 USA
(262) 781-3600
Symptom
Battery Pack
fuel gauge
LEDs fail to
progress from
1 to 2 to 3 to 4
LED lit
Possible Cause(s)
Charger needs to be reset
Progressive Charge Indication – indicates the approximate remaining charge
time or if there is enough charge level on the pack to complete the job at hand.
3 Amp Charger – charges battery pack in 30 minutes or less.
Faulty Battery Pack
Fuel Gage LED lights will progress from 1 to 2 to 3 to 4 LED lit as Battery Pack
is charged – if no progression is seen the Charger or Battery Pack is faulty; the
internal temperature of the battery became too high, was subjected to water or
is defective.
first LED only,
stays blinking
– no
progression
Battery Pack
connected to
Charger.
Alternately
flashing
red/green
Charger
lights.
Battery Pack
shows four
lights, and
then – battery
pack is
‘dead’– fuel
gauge drops
to NO lights
after one or
two holes /
screw
insertions, etc
Solution(s)
no progression - this can also take place occasionally, if power is
interrupted and reapplied. Unplug Charger and remove Battery Pack for
one minute (60 seconds). Plug Charger back in and reinstall Battery
Pack on Charger
Battery Pack Protection
Battery Pack Protection - to protect itself from damage and extend its life, the
battery pack’s intelligent circuit monitors current draw and temperature. In
extremely high torque, binding, stalling, and short circuit situations, the battery
pack will turn OFF the tool if the current draw becomes too high. In these
situations, the tool will "buzz" for about 5 seconds before it turns OFF. To
reset, pull and release the trigger. If this happens repeatedly, the battery pack
will shut down and need to be placed on the charger to reset. Under extreme
circumstances, the internal temperature of the battery could become too high;
the battery pack will then shut off. Remove the battery pack from the tool and
place it on the charger to reset it.
Bad connection between
Battery Pack and Charger
Clean Battery Pack terminals. NOTE: Before checking battery pack terminals
inside connector block or fuses F1 or F2 unplug the Charger from power
source and let it sit for 3-4 minutes before disassembling – this allows circuit
board capacitor to self discharge.
Faulty Battery Pack
Pack may not be accepting charge or Battery Pack electronics FET may be
faulty. Attempt to charge Battery Pack on known-good Charger.
Battery Pack temperature
dropped below 14ºF (-10ºC)
during charge
Move Charger and Battery Pack to warmer environment. Allow to warm up,
and then re-start charge.
Pack temperature higher than
149ºF (65ºC) at start of
charge
Allow Battery Pack to cool – 10 to 30 minutes - to appropriate temperature
range [<149ºF (65ºC)] before attempting to charge.
Water inside Battery Pack or
Charger as a result of
condensation from bringing
cold product into a warm
environment
Allow Battery Pack or Charger to dry out.
DEFECTIVE Battery Pack
Battery Pack fuel gauge drops to NO lights after one or two holes / screw
insertions – no LEDs lit or blinking.
This bulletin is for informational purposes. PLEASE NOTE ON SERVICE PARTS LIST: 54-04-1810, 54-06-2610