EXPORT POWERDRIVE CHARGER (ONBOARD)
Charging a Battery Pack that has Low Voltage
Page 4-34
2008 Export Battery Charger Maintenance and Service Manual
4
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WARNING
• The relay wiring must be properly connected prior to placing the charger back into normal
service. Failure to remove the jumper wire and properly connect the relay wiring could result
in property damage, severe personal injury, or death.
10. Install the charger cover and install the charger in the vehicle.
See Onboard Charger Installation on
page 4-36.
11. Plug the AC cord into an electrical outlet.
12. Allow the charger to continue charging the batteries until the charger shuts off automatically.
13. When the charge cycle is complete, test the batteries again. If the battery pack voltage is above 34 volts
and the vehicle will not operate, it will be necessary to troubleshoot the vehicle’s electrical system to
determine which electrical component has failed.
See Section 11 – Electrical System and Testing in
the appropriate maintenance and service manual.
Figure 4-27 PowerDrive Onboard Charger Wiring Diagram (Relay Bypassed)
RELAY BYPASS
JUMPER WIRE
RELAY BYPASS
JUMPER WIRE
BLACK
BLACK (6)
DC CORDSET
RED
RED
RED
RED
BLUE
BLUE
BLUE
BLACK
BLACK
BLACK
AC CIRCUIT
BREAKERS
AC CORD
CONTROL
BOARD
GREEN or GREEN/YELLOW
TA
N
TA
N
DIODES WITH
HEATSINK
AMMETER
TRANSFORMER
PRIMARY
COIL
SECONDARY
COIL
CASE
GROUND
BLACK or BROWN
WHITE or BLUE
BLACK
BLACK
BLACK
BLACK(1)
BLA
C
K
BLA
C
K
BLACK
BLACK
BLACK (1)
TAN (1)
TAN (6)
T
A
N (1)
T
A
N (6)
T
A
N (5)
T
A
N (4)
T
A
N (3)
T
A
N (2)
BLA
C
K
BLA
CK
BLA
C
K
BLA
C
K
BLA
C
K
BLACK
BLACK
BLACK
BLK
BLK
BLACK (6)
RELAY
9
7
6
4
3
1
A
B
FUSE
1
2
3
4
5
6
TERMINAL #
BLUE
BLACK
RED
A
C
V
O
LT
A
GE SELECT
OR SWITCH
