EXPORT POWERDRIVE CHARGER (ONBOARD)
Charger Repairs
Page 4-26
2008 Export Battery Charger Maintenance and Service Manual
4
AC Circuit Breaker
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 wires from the AC circuit breaker.
4. Place the continuity test probes on the two terminals of the AC circuit breaker. The tester should indicate
continuity. If the tester does not indicate continuity, replace the AC circuit breaker.
CHARGER REPAIRS
See General Warning, Section 1, Page 1-1.
ý
WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 4-5, Page 4-7).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet,
disconnect the DC cord from the vehicle, and remove the battery charger from the vehicle.
See Onboard Charger Removal on page 4-35.
DC CORD
DC Cord Removal
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 DC cord black wire (4) from the ammeter by loosening the nut (1). Support the terminal as
the nut is loosened to prevent rotation of the connection
(Figure 4-24, Page 4-27)
.
4. Remove nut attaching the red wire (6) of the charger DC cord to the heatsink.
5. Remove the wire tie that secures the DC cord wire to the secondary coil wire (tan).
6. Remove the wire tie on the DC cord near the strain relief bushing.
7. Disconnect the DC cord blue wire from the control board
(Figure 4-23, Page 4-27)
.
8. Using pliers, squeeze the strain relief bushing and remove the DC cord
(Figure 4-23, Page 4-27)
.
DC Cord Installation
1. Insert the leads of the new DC cord through the hole in the charger base.
2. Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18
in-lb (2.0 N·m)
(Figure 4-23, Page 4-27)
.
3. Attach the blue wire of the new DC cord to the control board
(Figure 4-23, Page 4-27)
.
4. Attach black wire of the new DC cord to ammeter. Install nut (1) onto post of ammeter slightly more than
finger tight. While holding the inside nut (2), tighten the outside nut (1) 1/4 turn
(Figure 4-24, Page 4-27)
.
See following CAUTION.