EXPORT IQ PLUS CHARGER (ONBOARD)
Test Procedures
2008 Export Battery Charger Maintenance and Service Manual
Page 6-13
6
TEST PROCEDURE 3 – AC POWER AND CONTINUITY CHECK OF AC CIRCUIT
See General Warning, Section 1, Page 1-1.
1. Disconnect the AC power supply cord from the wall outlet.
2. Check the AC circuit breakers on the front of the charger and reset it if necessary.
3. Check the AC line fuse or circuit breaker in the storage facility.
4. With a multimeter set to 500 volts AC, check incoming AC voltage. Insert multimeter test probes into AC
wall outlet; voltage should be within the range specified in the following chart. If proper voltage is not
present and the voltage selector switch is set for the correct voltage for your area, have building wiring
checked by a licensed electrical contractor.
5. Check continuity of the AC circuit.
5.1. Remove the battery charger from the vehicle.
See Onboard Charger Removal on page 6-34.
5.2. Remove the charger cover.
5.3. Bypass the relay.
See Charging a Battery Pack that has Low Voltage on page 6-31.
5.4. With relay bypassed, there should be continuity across the AC cord blades
(Figure 6-9,
Page 6-14)
.
6. If the circuit is not complete, check the wiring of the AC cord, AC cord reel, transformer primary coil wires
(21), internal AC circuit breakers (13), and voltage selector switch (9)
(Figure 6-4, Page 6-6)
.
7. If the charger is wired correctly, check the continuity of the AC cord, AC cord reel, transformer primary
coil, and the internal AC circuit breaker individually.
See Test Procedure 8 – Continuity on page 6-18.
Figure 6-8 Control Board
SETTING ON AC VOLTAGE
SELECTOR SWITCH
MINIMUM AC VOLTAGE
PERMITTED
MAXIMUM AC VOLTAGE
PERMITTED
100 Volts AC
95
105
200 Volts AC
190
210
220 Volts AC
209
231
240 Volts AC
228
252
BLUE WIRE
FROM DC CORD
BLUE WIRE FROM RELAY
BLACK WIRE FROM RELAY
BLACK OR BROWN WIRE
FROM AC CORD
BLACK WIRE FROM
RELAY
WHITE OR BLUE
WIRE FROM
AC CORD
RED WIRE FROM RELAY
RED WIRE
FROM HEATSINK
