EXPORT IQ PLUS CHARGER (ONBOARD)
Test Procedures
2008 Export Battery Charger Maintenance and Service Manual
Page 6-15
6
7. On rare occasions, a single fuse link may blow due to excessive heat. This can be caused by a loose
internal fuse connection. Check all three fuse connections inside the charger to be sure they are clean
and tight. The proper tightness for the fuse link connections is 22 in-lb (2.5 N·m).
8. Ensure that the charger is wired properly and all connections are clean and tight.
See following CAU-
TION.
CAUT ION
• If connections are not clean and tight, excessive heat will be created and the charger may
become damaged.
Test Procedure 4B – Both Diodes Failed
See General Warning, Section 1, Page 1-1.
To check the diodes, use Test Procedure 4A – Single Diode Failure on page 6-14. If both diodes have failed
closed, both charger fuse links will be blown. If both diodes have failed open, the relay will close and the trans-
former will hum, but the ammeter will not indicate any output and the AC circuit breaker may trip off. If both
diodes have failed open or closed, the entire heatsink must be replaced. To determine why both diodes failed:
1. Check the batteries and the receptacle to ensure that they are wired in the correct polarity.
(Figure 6-2,
Page 6-3)
.
2. Make sure the charger is wired correctly: The DC cord red wire should be connected to the center ter-
minal of the heatsink, the DC cord blue wire should be connected to the control board, and the DC cord
black wire should be connected to the left side of the ammeter (when viewed from inside the charger)
(Figure 6-4, Page 6-6)
. If a reverse polarity connection is made between the charger and the batteries,
both fuse links will blow when the DC cord is connected to the vehicle, whether or not the AC cord is
plugged into an outlet.
3. Make sure the charger is wired to the vehicle correctly; the DC cord red wire should be connected to the
same large solenoid post as the 6-gauge red wire connected to the positive (+) post of battery no. 1. The
DC cord blue wire should be connected to the sense lead fuse. The DC cord black wire should be con-
nected to the terminal block located on the vehicle component mounting plate
(Figure 6-2, Page 6-3)
.
If a reverse polarity connection is made between the charger and the batteries, both fuse links will blow
when the DC cord is connected to the vehicle, whether or not the AC cord is plugged into an outlet.
4. On rare occasions, both diodes may fail as a result of a lightning strike at the charging location.
Figure 6-10 Diode Test
Figure 6-11 Diode Test – Probes Reversed
DISCONNECTED
SECONDARY
COIL WIRE
