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EXPORT IQ PLUS CHARGER (ONBOARD)
Troubleshooting
Page 6-8
2008 Export Battery Charger Maintenance and Service Manual
6
IQ PLUS ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE
SYMPTOM
POSSIBLE CAUSES
CORRECTIVE ACTION
Relay does not close, no transformer
hum and ammeter does not move
Batteries disconnected
Connect batteries
(Figure 6-5, Page 6-11)
Battery voltage is too low
Test Procedure 1 – Battery Voltage on
page 6-10
Improper vehicle or battery charger wiring
See
Figure 6-2, Page 6-3
,
Figure 6-4,
Page 6-6 and
Figure 6-5, Page 6-11
DC circuit
Test Procedure 5 – Charger DC Circuit
Continuity Test on page 6-16
Onboard computer malfunction
Test Procedure 2 – Control Board on
page 6-12
Gray sense lead fuse is blown
Test Procedure 1 – Battery Voltage on
page 6-10
Control board malfunction
Test Procedure 2 – Control Board on
page 6-12
Relay closes with an audible click but
no transformer hum and ammeter does
not move
Improper AC line voltage
Test Procedure 3 – AC Power and
Continuity Check of AC Circuit on
page 6-13
Failed AC plug and cord
Test Procedure 3 – AC Power and
Continuity Check of AC Circuit on
page 6-13
Failed AC cord reel
Test Procedure 8 – Continuity on
page 6-18
Internal AC breaker
Test Procedure 3 – AC Power and
Continuity Check of AC Circuit on
page 6-13
Transformer primary coil
Test Procedure 6 – Transformer on
page 6-16
Relay
Test Procedure 8 – Continuity on
page 6-18
Relay closes and transformer hums but
ammeter does not move
Blown charger fuse
Test Procedure 4 – Diodes on page 6-14
Both Diodes failed
Test Procedure 4B – Both Diodes Failed
on page 6-15
Onboard computer malfunction
Test Procedure 2 – Control Board on
page 6-12
Failed transformer
Test Procedure 6 – Transformer on
page 6-16
Failed ammeter
Replace ammeter
Relay operates intermittently
Failed charger relay
Test Procedure 8 – Continuity on
page 6-18
Single charger fuse link blows
Diode failed
Test Procedure 4A – Single Diode Failure
on page 6-14
Loose internal fuse connection
Tighten connection
Both charger fuse links blow or
receptacle fuse link blows
Battery is wired in reverse polarity
Check vehicle wiring
DC cord is wired in reverse polarity
Check battery charger wiring
Both diodes failed
Test Procedure 4B – Both Diodes Failed
on page 6-15
Troubleshooting Guide continued on next page...