EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Charger Repairs
Page 3-30
2008 Export Battery Charger Maintenance and Service Manual
3
CHARGER REPAIRS
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
ý
WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 3-11, Page 3-13).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and
the DC plug from the vehicle charger receptacle.
DC CORD
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
DC Cord Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
See preceding
WARNING.
2. Remove the charger cover.
3. Remove the DC cord black wire (4) from the ammeter by loosening the nut (1). Support the terminal as
the nut is loosened to prevent rotation of the connection
(Figure 3-28, Page 3-30)
.
4. Remove nut attaching the red wire (6) of the charger DC cord to the heatsink.
5. Disconnect the DC cord blue wire from the blue wire of the voltage suppressor assembly connected to
the relay (coil) terminal
(Figure 3-27, Page 3-27)
.
6. Remove wire ties securing the blue wire to the black transformer wire. Note the location of the wire ties.
7. Using pliers, squeeze the strain relief bushing and remove the DC cord.
DC Cord Installation
1. Insert the leads of the new DC cord through the hole in the charger base.
2. Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18
in-lb (2.0 N·m)
(Figure 3-27, Page 3-27)
.
Figure 3-28 DC Cord Replacement
1
4
2
3
6