250amp battery charger wiring / no help from Crastman or Schumacher - Page 1
Forum section: electronics / beginners

author: Huff
author_rank: Newbie
timestamp: June 28, 2025, 11:55:07 am
content: No help from Schumacher or Craftsman on a wiring diagram.I have a Cmxcesm233 charger.Do I have the selector switch wired correctly? Ignore the heavy black wire in the bottom of the pic please.Look close at the transformer. Which connection to the transformer go? There are two empty slots that it could go to?Just trying to be short and to the point here.Thanks in advance

author: floobydust
author_rank: Super Contributor
timestamp: June 29, 2025, 06:50:47 pm
content: Welcome to the forumsYou mean 250A not 250volt? Craftsman? Please update the thread title for the search engines etc.CraftsmanCMXCESM233battery charger looks like a SchumacherSC1574maybe but not sure.I think your switch is 0499000051, 6 Position Rotary Switch, twist lock mount. Leads me to this wiring diagram.

author: Huff
author_rank: Newbie
timestamp: June 30, 2025, 10:52:14 am
content: Thank you. This could help.

author: Huff
author_rank: Newbie
timestamp: June 30, 2025, 05:36:27 pm
content: My original post is not clear.Let me try again.The transformer pic shows a black wire not hooked up. I could go to one of the two empty slots. Which one should it got to?Does anyone have a picture that shows this?

author: floobydust
author_rank: Super Contributor
timestamp: July 01, 2025, 06:08:51 am
content: I can't see the second (possible) place or "slot" you refer to, to connect the black wire.Where is it?

author: Huff
author_rank: Newbie
timestamp: July 01, 2025, 09:14:08 am
content: All the way to the right side of the pic. There is a slot at the red winding wire.Sorry about the bad pic. I did no pay close enough attention when posting it. Thanks for taking a interest.

author: floobydust
author_rank: Super Contributor
timestamp: July 02, 2025, 03:35:10 am
content: Uh orange wire is on the right. Most pictures show the black at the far end, connects to thermal fuse. The reddish varnish on the transformer wire has me a bit confused why the different colour.

author: Huff
author_rank: Newbie
timestamp: July 02, 2025, 08:16:44 pm
content: Thank all of you.I will hook it up this way and see what happens. I will post the results.

author: floobydust
author_rank: Super Contributor
timestamp: July 02, 2025, 11:44:13 pm
content: I can't see enough from the picture to tell where the thermal fuse goes. One end of it will be the black wire, the other end of the thermal fuse goes into the primary winding end.Right now that looks like between the red and blue is where the black wire connects - IF the thermal fuse then leads off to the winding. Need another pic.If you're not 100% sure of the wiring, you can power this up using a dim light bulb in series, or take ohmmeter readings between the transformer (primary) terminals and post them here.The black wire is (hot) the one to not mix up or boomski.

author: Huff
author_rank: Newbie
timestamp: July 03, 2025, 12:14:49 pm
content: Thanks for taking a interest in helping me here. I am not good with readings and such. So here are more and better pics to be sure the sector switch is wired correctly and where does the black wire go on the windings?Thanks in advance.

author: Huff
author_rank: Newbie
timestamp: July 03, 2025, 12:16:34 pm
content: More pics

author: BILLPOD
author_rank: Frequent Contributor
timestamp: July 03, 2025, 12:31:35 pm
content: Good Morning Huff, I recommend you 'wring out' the windings on the xfmr. and make a table of the resistances of the connections. This is so that you don't create a short circuit,and be able to distinguishthe primary winding from the secondary, (primary will have a higher resistance. You may have to temporarily disconnect the colored wires, as they could skew the readings.

author: Seekonk
author_rank: Super Contributor
timestamp: July 03, 2025, 01:42:41 pm
content: Use a 100W or higher incandescent lamp to limit current. This will be safe on all windings. Voltage will be lower voltage but it will give ratios and phasing.

author: UnijunctionTransistor
author_rank: Frequent Contributor
timestamp: July 03, 2025, 02:03:46 pm
content: I can see what happened. The terminal where the black wire was originally crimped to, snapped off.If I had to take an educated guess, it would be where I circled in the image. Follow the previous recommendations when testing.

author: Gregg
author_rank: Super Contributor
timestamp: July 03, 2025, 06:27:26 pm
content: The post by Unijunction Transistor makes perfect sense by what I can see from the pictures. The black wire is mains line input switched by what might be a timer and the only logical connection not already used is the primary of the transformer.However,, it still would be prudent to test it with an incandescent lamp in series

author: floobydust
author_rank: Super Contributor
timestamp: July 03, 2025, 08:09:04 pm
content: Hey I see you moved wires around on the selector switch, swapped yellow, red and orange. What is going on. It looks better lol.You can sort those out later- no danger, it will just mean the low/med/high outputs are jumbled.Really, the black wire connection is important and my best guess is to the bobbin middle (between red/blue) point, like pic above and as I said before.A pic of the transformer top area would show how the thermal fuse is wired.I did find datasheets for the selector switch Defond DYU-38-01 or 02 aka 499000051, 499000058.

author: Huff
author_rank: Newbie
timestamp: July 04, 2025, 03:38:09 pm
content: Does this help. Floobydust you were asking for a top view of the wire connections. The yellow circles show the empty slots the black wire could connect to.

author: floobydust
author_rank: Super Contributor
timestamp: July 04, 2025, 06:57:51 pm
content: Yes that confirms the wiring to the thermal fuse. I was wondering about the reddish varnish wire what that was about, it's just a stub.So black does connect to the bobbin middle, between the red and blue wires like the pic in Reply #13.

author: Huff
author_rank: Newbie
timestamp: July 04, 2025, 07:02:20 pm
content: Wow. This is great to have a finite answer. It might be a day or so before I can get back to this project but I will post the outcome.Thanks so much.