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EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Test Procedures
Page 3-22
2008 Export Battery Charger Maintenance and Service Manual
3
6. If the circuit is not complete, check the wiring of the AC cord (16), transformer primary coil wires (21),
internal AC circuit breakers (13), voltage selector switch (9), and jumper wires
(Figure 3-12, Page 3-17).
7. If the charger is wired correctly, check the continuity of the AC cord, transformer primary coil, internal AC
circuit breakers, and the jumper wires individually.
See Test Procedure 8 – Continuity on page 3-26.
8. When troubleshooting and repairs are complete, remove the jumper wire and properly connect the relay
wiring.
See following WARNING.
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WARNING
• The relay wiring must be properly connected prior to placing the charger back into normal
service. Failure to remove the jumper wire and properly connect the relay wiring could result
in property damage, severe personal injury, or death.
TEST PROCEDURE 4 – DIODES
Use Test Procedure 4A – Single Diode Failure on page 3-22 for single diode failures and testing of individual
diodes. If both diodes have failed, use Test Procedure 4B – Both Diodes Failed on page 3-23.
Test Procedure 4A – Single Diode Failure
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
A single diode failure is indicated by the failure of one fuse link (closed circuit diode) or by the charger output
being low (open circuit diode). If a diode has failed, the entire heatsink must be replaced. To check diodes:
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Disconnect one transformer secondary coil wire from the diode terminal
(Figure 3-21, Page 3-23).
4. Using a low voltage continuity tester or multimeter set to the diode test function, connect the red (+) test
probe to the diode mounting plate and the black (–) test probe to a diode terminal and note the reading
(Figure 3-21, Page 3-23).
5. Reverse test probes and check each diode again and note the reading
(Figure 3-22, Page 3-23).
A
diode is designed to conduct current in one direction only. If a diode conducts current (shows continuity)
in both directions, the entire heatsink with diodes must be replaced. If a diode does not conduct current
(does not show continuity) in either direction, the entire heatsink must be replaced.
Figure 3-20 AC Cord Test
AC plug may have different appearance
depending on geographic region.