EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Charger Repairs
Page 3-32
2008 Export Battery Charger Maintenance and Service Manual
3
TRANSFORMER
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
Transformer 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. Note the locations of wire ties and remove the wire ties.
4. Disconnect the black primary coil leads from the AC circuit breakers and the voltage selector switch
(Figure 3-11, Page 3-13 and Figure 3-12, Page 3-17)
.
5. Disconnect the two tan secondary coil transformer wires from heatsink.
6. Disconnect the two black secondary coil transformer wires from the fuse.
7. Remove the four bolts and nuts that mount the transformer to the case and remove the transformer.
Transformer Installation
1. Install the transformer with the secondary coil to the rear of the charger case. Tighten the four bolts and
nuts to 28 in-lb (3.2 N·m)
(Figure 3-12, Page 3-17)
.
2. Connect one secondary coil transformer wire (black) to one terminal of the fuse. Tighten nut to 22 in-lb
(2.5 N·m).
3. Connect the other secondary coil transformer wire (black) to the remaining terminal of the fuse. Tighten
nut to 22 in-lb (2.5 N·m).
4. Connect one secondary coil transformer wire (tan) to the top terminal post of the heatsink. Tighten nut
to 18 in-lb (2.0 N·m).
5. Connect the other secondary coil transformer wire (tan) to the bottom terminal post of the heatsink.
Tighten nut to 18 in-lb (2.0 N·m).
6. Connect the black primary coil transformer wire marked 1 to the top terminal of the top AC circuit breaker.
7. Connect the black primary coil transformer wire marked 6 to the top terminal of the bottom AC circuit
breaker.
8. Connect each of the remaining black primary coil transformer wires marked 2, 3, 4, and 5 to the corre-
sponding terminals marked on the voltage selector switch.
9. Set the voltage selector switch to the appropriate voltage matching the incoming AC electrical service
that will be used to power the charger.
10. 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.
11. Install the charger cover and check charger for proper operation.
