EXPORT POWERDRIVE CHARGER (ONBOARD)
Test Procedures
Page 4-24
2008 Export Battery Charger Maintenance and Service Manual
4
7. Place the red (+) probe into the top-center opening of the cord reel receptacle (1). Test for continuity on
the cord reel AC plug (2) on each of the flat blades and then on the round pin of the AC plug. The tester
should indicate continuity on only the round pin. If any other reading is obtained, the retractable cord reel
must be replaced.
8. If the correct readings are obtained in all of the previous steps, the retractable cord reel is functioning
properly.
DC Cord
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle.
See Onboard Charger Removal on page 4-35.
2. Remove the charger cover.
3. To check the continuity of the DC cord, disconnect the black wire of the DC cord from the ammeter
(Figure 4-23, Page 4-27).
4. Disconnect the red wire of the DC cord from the heatsink.
5. Disconnect the blue wire from the control board.
6. Using a multimeter set for 200 ohms, place the red (+) probe on the red wire of the DC cord. Test for con-
tinuity on each of the wires on the other end of the DC cord. The tester should indicate continuity on the
red DC cord wire only. If any other reading is obtained, the DC cord must be replaced.
7. Place the red (+) probe on the blue wire of the DC cord. Test for continuity on each of the wires on the
other end of the DC cord. The tester should indicate continuity on the blue DC cord wire only. If any other
reading is obtained, the DC cord must be replaced.
8. Place the red (+) probe on the black wire of the DC cord. Test for continuity on each of the wires on the
other end of the DC cord. The tester should indicate continuity on the black DC cord wire only. If any other
reading is obtained, the DC cord must be replaced.
Transformer
The PowerDrive battery charger transformer has two sets of coils: a primary coil and a secondary coil
(Figure 4-27, Page 4-34)
.
Primary Coil
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle.
See Onboard Charger Removal on page 4-35.
2. Remove the charger cover.
3. Disconnect the black wires marked 1 and 6 from the AC circuit breakers.
4. Disconnect the wires marked 2, 3, 4 and 5 from the voltage selector switch.
5. Place the continuity tester probes on the primary coil transformer wires disconnected above in pairs until
all of the combinations in the following chart have been tested.
6. If the continuity readings agree with the chart, replace the voltage selector switch. If the continuity read-
ings differ from the chart, replace the transformer.
Secondary Coil
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle.
See Onboard Charger Removal on page 4-35.
2. Remove the charger cover.
3. Remove the transformer (tan) secondary coil wire from the upper terminal of the heatsink
(Figure 4-5,
Page 4-7)
.