EXPORT POWERDRIVE CHARGER (ONBOARD)
Troubleshooting
2008 Export Battery Charger Maintenance and Service Manual
Page 4-9
4
EXPORT POWERDRIVE 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.
See
Figure 4-6,
Page 4-12
through Figure 4-9,
Page 4-13
Battery voltage is too low
Test Procedure 1 – Battery Voltage on
page 4-11
Improper vehicle or battery charger wiring
See
Figure 4-2, Page 4-3
,
Figure 4-3,
Page 4-3
,
Figure 4-5, Page 4-7
,
Figure 4-6, Page 4-12
,
Figure 4-7,
Page 4-12
,
Figure 4-8, Page 4-12
and
Figure 4-9, Page 4-13
DC circuit
Test Procedure 5 – Charger DC Circuit
Continuity Test on page 4-18
Onboard computer malfunction
Test Procedure 2 – Control Board on
page 4-13
Gray sense lead fuse is blown
Test Procedure 1 – Battery Voltage on
page 4-11
Control board malfunction
Test Procedure 2 – Control Board on
page 4-13
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 4-15
Failed AC plug and cord
Test Procedure 3 – AC Power and
Continuity Check of AC Circuit on
page 4-15
Failed AC cord reel
Test Procedure 8 – Continuity on
page 4-21
Internal AC breaker
Test Procedure 3 – AC Power and
Continuity Check of AC Circuit on
page 4-15
Transformer primary coil
Test Procedure 6 – Transformer on
page 4-19
Relay
Test Procedure 8 – Continuity on
page 4-21
Relay closes and transformer hums but
ammeter does not move
Blown charger fuse
Test Procedure 4 – Diodes on page 4-16
Both Diodes failed
Test Procedure 4B – Both Diodes Failed
on page 4-17
Onboard computer malfunction
Test Procedure 2 – Control Board on
page 4-13
Failed transformer or voltage switch
Test Procedure 6 – Transformer on
page 4-19
Failed ammeter
Replace ammeter
Relay operates intermittently
Failed charger relay
Test Procedure 8 – Continuity on
page 4-21
Single charger fuse link blows
Diode failed
Test Procedure 4A – Single Diode Failure
on page 4-16
Loose internal fuse connection
Tighten connection
Troubleshooting Guide continued on next page...