EXPORT IQ PLUS CHARGER (EXTERNAL)
Charger Repairs
2008 Export Battery Charger Maintenance and Service Manual
Page 5-31
5
CAUT ION
• Do not allow ammeter post to rotate as the nut is tightened. Rotation of the post could result
in a damaged ammeter.
5. Install the charger cover.
6. Plug the charger into the vehicle and check ammeter for proper operation.
FUSE LINK
See General Warning, Section 1, Page 1-1. See additional WARNING on page 5-1.
Fuse Link Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Remove both black secondary coil transformer wires and the black jumper wire (18) from the back of the
fuse link assembly (11)
(Figure 5-7, Page 5-13)
.
4. Remove screws from the front of the charger and remove the fuse link assembly.
Fuse Link Installation
1. Place clear plastic cover over fuse assembly (11) and install mounting screws from front of charger face.
The center branch of the fuse assembly should be in the upper left corner when viewed from the front
of the charger.
2. Install the jumper wire (18) over the center branch of the fuse assembly and ammeter post
(Figure 5-7,
Page 5-13)
. Tighten to 22 in-lb (2.5 N·m).
3. Install a secondary coil transformer wire (black) onto one of the two remaining terminals on the back of
the fuse assembly. Install the remaining secondary coil transformer wire (black) to the remaining termi-
nal. Tighten to 27 in-lb (3.0 N·m).
4. Install the charger cover.
VOLTAGE SUPPRESSOR
See General Warning, Section 1, Page 1-1. See additional WARNING on page 5-1.
The voltage suppressor, which is incorporated into a wire assembly in the charger, protects the onboard com-
puter by capturing very high, but very brief voltage spikes which occur due to the collapse of the electrical field
in the charger relay when the charger is disconnected from the vehicle.
See also Test Procedure 8 – Conti-
nuity on page 5-22.
Voltage Suppressor Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Remove nut attaching voltage suppressor (18-gauge red wire) (2) to heatsink
(Figure 5-21, Page 5-32)
.
4. Disconnect the limiter (4) at the quick disconnect terminal on the relay side.
5. Disconnect the voltage suppressor wire assembly from charger relay (3).
6. Remove the white fiberglass sleeve from the red heatsink wire. Retain the sleeve for use when installing
the new voltage suppressor.