EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Charger Repairs
2008 Export Battery Charger Maintenance and Service Manual
Page 3-31
3
3. Attach the blue wire of the new DC cord to the blue wire of the voltage suppressor assembly connected
to the relay (coil) terminal.
4. Attach the black wire (4) of the new DC cord to ammeter. Install nut (1) onto post of ammeter slightly more
than finger tight. While holding the inside nut (2), tighten the outside nut (1) 1/4 turn
(Figure 3-28,
Page 3-30)
.
See following CAUTION.
CAUT ION
• Do not allow ammeter post to rotate as the nut is tightened. Rotation of the post could result
in a damaged ammeter.
5. Using pliers, put the strain relief bushing on the cord and insert it into the charger base.
6. Secure the blue wire to the black wire in the locations noted in step 6 of DC Cord Removal.
7. Tie the wires together as they were before the wire tie was removed.
See following WARNING.
ý
WARNING
• Make sure wiring is properly routed and secured. Failure to properly route and secure wiring
could result in charger malfunction, property damage, or severe personal injury.
8. Position the charger cover on the base. Install the mounting screws, starting with the bottom holes.
Tighten the screws to 11 in-lb (1.2 N·m).
HEATSINK
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
Heatsink Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
See WARNING on
page 3-30.
2. Remove the charger cover.
3. Remove both secondary coil transformer wires (tan) from the heatsink
(Figure 3-11, Page 3-13 and
Figure 3-12, Page 3-17)
.
4. Remove the two red wires from the heatsink.
5. Remove the nuts and bolts that secure the heatsink to the case.
Heatsink Installation
1. Place heatsink against charger base. Make sure clear plastic insulator sheet is between the heatsink and
the charger base. Install the nuts and bolts that secure the heatsink to the case. Tighten the bolts to 22
in-lb (2.5 N·m)
(Figure 3-11, Page 3-13
and
Figure 3-12, Page 3-17)
.
2. Connect the red wire from the DC cord and the red wire from the charger relay to the center terminal post
on the heatsink. Tighten nut to 18 in-lb (2.0 N·m).
3. Connect one of the secondary coil transformer wires (tan) to the bottom terminal post of the heatsink.
Tighten nut to 18 in-lb (2.0 N·m).
4. Connect the other secondary coil transformer wire (tan) to the top terminal post of the heatsink. Tighten
nut to 18 in-lb (2.0 N·m).
5. Install the charger cover and check charger for proper operation.
