EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Test Procedures
Page 3-24
2008 Export Battery Charger Maintenance and Service Manual
3
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Using a continuity tester (CCI P/N 1011273) or multimeter (CCI P/N 1011480) set to 200 ohms, connect
the test probes to the pins marked (+) and (–) on the DC plug
(Figure 3-23, Page 3-24)
. Note the read-
ing.
3. Reverse the test probes and check the DC plug again
(Figure 3-24, Page 3-24)
. The circuit should show
continuity in only one direction.
4. If the circuit does not show continuity in either direction and the charger fuse is not blown, individually
check all connections and the continuity of the DC cord and ammeter.
See Test Procedure 8 – Conti-
nuity on page 3-26.
Also check the diodes (heatsink).
See Test Procedure 4 – Diodes on page 3-22.
5. If the circuit shows continuity in both directions, a short circuit exists in the charger DC circuit, usually
caused by failed diodes.
See Test Procedure 4 – Diodes on page 3-22.
If diodes have not failed, check
the DC cord for a short circuit.
See Test Procedure 8 – Continuity on page 3-26.
6. Remove the DC cord blue wire from the red wire connected to the charger relay and check continuity
between the positive and negative pins and middle pin on the DC plug
(Figure 3-11, Page 3-13)
. There
should be no continuity.
TEST PROCEDURE 6 – TRANSFORMER
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns. If the transformer
has failed, the ammeter will indicate low output or no output; however, the transformer may hum. A blown AC
line fuse or tripped AC circuit breaker in the charger or the storage facility may be caused by an improperly
wired charger, an improper setting of the AC voltage selector switch, or a failed transformer.
An AC circuit test should be done before performing this test procedure to ensure the continuity of the AC
cord, internal AC circuit breakers, and charger wiring.
See Test Procedure 3 – AC Power and Continuity
Test of AC Circuit on page 3-21.
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Disconnect transformer secondary coil wires from the heatsink
(Figure 3-25, Page 3-25)
.
4. To apply AC power directly to the transformer primary coil, bypass the relay.
See Charging a Battery
Pack that has Low Voltage on page 3-37. See following DANGER.
Figure 3-23 DC Plug Test
Figure 3-24 DC Plug Test – Reversed Probes
PULL HERE
PULL HERE
PULL HERE
PULL HERE
POSITIVE PIN
NEGATIVE PIN
PULL HERE
PULL HERE
PULL HERE
PULL HERE
POSITIVE PIN
NEGATIVE PIN
