EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Charging a Battery Pack that has Low Voltage
2008 Export Battery Charger Maintenance and Service Manual
Page 3-37
3
CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
If battery pack voltage is below 34 volts, the charger will not activate. The charger relay will have to be
bypassed to activate the charger.
See following WARNING.
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WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 3-11, Page 3-13).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and
the DC plug from the vehicle charger receptacle.
1. Turn key switch OFF and place the Forward/Reverse handle in the NEUTRAL position. Leave the bat-
teries connected.
2. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
3. Remove the charger cover.
4. To apply AC power directly to the transformer primary coil, the relay must be bypassed.
4.1. To bypass the relay, locate the black wire that goes from the circuit breaker to terminal 9 on the
relay. Disconnect the black wire from the relay terminal
(Figure 3-31, Page 3-38)
.
4.2. Disconnect the brown wire from relay terminal 6.
4.3. Use a jumper wire with alligator clips to connect the black wire from relay terminal 9 to the brown
wire from relay terminal 6
(Figure 3-31, Page 3-38)
.
4.4. Disconnect the black wire from relay terminal 7.
4.5. Disconnect the blue wire from relay terminal 4.
4.6. Use a jumper wire with alligator clips to connect the black wire from relay terminal 7 to the blue wire
from relay terminal 4
(Figure 3-11, Page 3-13)
.
See following DANGER.
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DANGER
• Do not touch any wire or component in the battery charger while AC power is present. Failure
to heed this warning will result in an electric shock.
5. Plug the DC cord into the charger receptacle first, then plug the AC cord into an electrical outlet.
6. The charger should activate and begin to charge the batteries. Allow the charger to operate for one or
two hours.
See following WARNING.
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WARNING
• Do not leave the vehicle unattended while it is charging. A charger operating with a bypassed
relay could short circuit and possibly cause a fire.
7. After one or two hours, disconnect the charger AC cord from the electrical outlet first. Then disconnect
the DC cord from the charger receptacle in the vehicle.
8. Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the
relay
(Figure 3-31, Page 3-38)
.
See following WARNING.
