EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Charger Repairs
Page 3-34
2008 Export Battery Charger Maintenance and Service Manual
3
FUSE LINK
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
Fuse Link Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
See WARNING on
page 3-30.
2. Remove the charger cover.
3. Remove both black secondary coil transformer wires and the buss bar (3) from the back of the fuse link
assembly
(Figure 3-29, Page 3-33)
.
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 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 buss bar (3) over the center branch of the fuse assembly and ammeter post
(Figure 3-29,
Page 3-33)
. 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) onto the remaining ter-
minal. Tighten to 22 in-lb (2.5 N·m).
4. Install the charger cover.
VOLTAGE SUPPRESSOR
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
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 Test Procedure 8 – Continuity
on page 3-26.
Voltage Suppressor Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
See WARNING on
page 3-30.
2. Remove the charger cover.
3. Remove nut attaching voltage suppressor (18-gauge red wire) to heatsink.
4. Disconnect blue wire to DC cord at quick disconnect terminal.
5. Disconnect the voltage suppressor wire assembly from charger relay.
Voltage Suppressor Installation
Install in reverse order of removal. Tighten nut attaching voltage suppressor (18-gauge red wire) to heatsink
to 18 in-lb (2.0 N·m).