EXPORT POWERDRIVE CHARGER (ONBOARD)
Charger Repairs
Page 4-32
2008 Export Battery Charger Maintenance and Service Manual
4
CHARGER AC CORD AND RETRACTABLE CORD REEL
See General Warning, Section 1, Page 1-1.
Short AC 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.
See WARNING on page 4-26.
2. Remove the charger cover.
3. Disconnect the AC cord black wire from the AC circuit breaker
(Figure 4-26, Page 4-31)
.
4. Disconnect the AC cord white wire from the control board.
5. Disconnect the AC cord green wire from the charger base
(Figure 4-26, Page 4-31)
.
6. Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger.
Short AC Cord Installation
1. Insert the black, white, and green leads of the new AC cord into the charger through the hole in the
charger face
(Figure 4-26, Page 4-31)
.
2. Connect the black wire and white wire to the control board
(Figure 4-5, Page 4-7)
. Connect the green
wire to the charger base. Tighten the screw on the green (ground) wire terminal to 18 in-lb (2.0 N·m).
3. Position the strain relief bushing on the AC cord.
4. Using pliers, install the strain relief bushing and AC cord into the mounting hole in the charger face.
5. Install the charger cover and install the charger in the vehicle.
See Onboard Charger Installation on
page 4-36.
6. Check charger for proper operation.
Retractable AC Cord Reel Removal
1. Disconnect retractable AC cord from AC outlet.
See Onboard Charger Removal on page 4-35.
See
WARNING on page 4-26.
2. Remove the charger cover.
3. Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord
reel by gently cutting the heatshrink tubing
(Figure 4-20, Page 4-22)
.
4. Disconnect the short AC cord from the retractable cord reel.
Retractable AC Cord Reel Installation
Install in reverse order of removal.
