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EXPORT POWERDRIVE CHARGER (ONBOARD)
Charging a Battery Pack that has Low Voltage
2008 Export Battery Charger Maintenance and Service Manual
Page 4-33
4
CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE
See General Warning, Section 1, Page 1-1.
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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.
If battery pack voltage is below 34 volts, the charger will not activate. The charger relay will have to be
bypassed to activate the charger.
1. Turn key switch OFF and place the Forward/Reverse switch in the NEUTRAL position.
2. Disconnect the AC and DC cords and remove the battery charger from the vehicle.
See Onboard
Charger Removal on page 4-35.
See WARNING on page 4-26.
3. Remove the charger cover.
4. To apply AC power directly to the transformer primary coil, the relay must be bypassed.
4.1. To bypass the relay, locate the black wire that goes from the circuit breaker to terminal 9 on the
relay. Disconnect the black wire from the relay terminal
(Figure 4-27, Page 4-34)
.
4.2. Disconnect the black wire from relay terminal 6.
4.3. Use a jumper wire with alligator clips to connect the black wire from relay terminal 9 to the black wire
from relay terminal 6
(Figure 4-27, Page 4-34)
.
4.4. Disconnect the black wire from relay terminal 7.
4.5. Disconnect the black wire from relay terminal 4.
4.6. Use a jumper wire with alligator clips to connect the black wire from relay terminal 7 to the black wire
from relay terminal 4
(Figure 4-27, Page 4-34)
.
See following DANGER.
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DANGER
• Do not touch any wire or component in the battery charger while AC power is present. Failure
to heed this warning will result in an electric shock.
5. Install the charger cover and install the charger in the vehicle.
See Onboard Charger Installation on
page 4-36.
6. Plug the AC cord into an electrical outlet. The charger should activate and begin charging.
7. Allow to charge for one or two hours.
See following WARNING.
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WARNING
• Do not leave the vehicle unattended while it is charging. A charger operating with a bypassed
relay could short circuit and possibly cause a fire.
8. After one or two hours, disconnect the AC cord and remove the battery charger from the vehicle.
See
Onboard Charger Removal on page 4-35.
See WARNING on page 4-26.
9. Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the
relay
(Figure 4-27, Page 4-34)
.
See following WARNING.