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EXPORT POWERDRIVE CHARGER (ONBOARD)
Charger Repairs
2008 Export Battery Charger Maintenance and Service Manual
Page 4-27
4
CAUT ION
• Do not allow ammeter post to rotate as the nut is tightened. Rotation of the post could result
in a damaged ammeter.
5. Using pliers, put the strain relief bushing on the cord and insert it into the charger base.
6. Tie the wires together as they were before the wire ties were removed.
See following WARNING.
ý
WARNING
• Make sure wiring is properly routed and secured. Failure to properly route and secure wiring
could result in charger malfunction, property damage, or severe personal injury.
7. Position the charger cover on the base. Install the mounting screws, starting with the bottom holes.
Tighten the screws to 11 in-lb (1.2 N·m).
HEATSINK
Heatsink Removal
1. Disconnect the AC cord and remove the battery charger from the vehicle.
See Onboard Charger
Removal on page 4-35.
See preceding WARNING.
2. Remove the charger cover.
3. Remove both secondary coil transformer wires (tan) from the heatsink
(Figure 4-18, Page 4-20)
and
remove the two red wires from the heatsink.
4. Remove the nuts and bolts that secure the heatsink to the case.
Heatsink Installation
1. Place heatsink against charger base. Make sure clear plastic insulator sheet is between the heatsink and
the charger base. Install the nuts and bolts that secure the heatsink to the case. Tighten the bolts to 22
in-lb (2.5 N·m).
2. Connect the red wire from the DC cord and the red wire from the control board to the center terminal post
on the heatsink
(Figure 4-5, Page 4-7)
. Tighten nut to 18 in-lb (2.0 N·m).
Figure 4-23 DC Cord
Figure 4-24 DC Cord Replacement
RED WIRE
TO HEATSINK
STRAIN RELIEF
BUSHING
DC CORD
DC CORD
BLACK WIRE
TO AMMETER
DC CORD
BLUE WIRE TO
CONTROL BOARD
6
3
2
4
1