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During the initial state of the charge, the charger operates in a fixed-current mode. This means that the current will be held at a constant rate until the battery is charged to a bit over 18 Volts. During this phase, the output of the charger will not be 18 Volts. This is done for safety and battery preservation; forcing 18 Volts on a battery discharged down to 15 Volts or less could cause the battery to overheat. If no battery is connected, the charge controller may hold the output low until a battery insertion is detected.
The exact behavior of the charger depends on the chemistry for which it is designed, whether Nickel-Cadmium, Nickel-Metal Hydride, or Lithium ion. If the output of a known-good battery is 18 Volts after charging, and it has normal capacity, the charger is working properly.
However, a bad cell in the battery changes things. If you run a Ni-Cd battery down too far, the weakest cell in the battery may begin to reverse charge from the current coming from the other cells. This usually causes an internal short circuit, and the cell will be stuck at 0 Volts. A battery pack with one shorted cell will read 16.7 -16.9 Volts when fully charged, and the drill will not have the peak power it should. The charger will give you a battery fault indication if it is equipped to do so.
I have to be the bearer of bad news. These are mass produced to give you the lowest price possible. They are made in Keorea/Taiwan and unfortunately do not make replacement parts. These are sold to any company that pays enough to put their name on it. Shop force makes the same drill and several other brands. So when something goes bad you have to replace the entire drill (only comes in the combo pk). You can't buy seperate pieces. Try shop force or Master craft. They're similar to what you have. Found one on Ebay. IF you keep looking you can probably find a seller with just the charger. Good luck http://cgi.ebay.com/18V-Cordless-Drill-with-charger-battery-NEW_W0QQitemZ260460074195QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item3ca4a154d3&_trksid=p3286.c0.m14
You should probably contact Customer Service regarding this. I'd say it's a problem with the batteries rather than the chargers considering this looks like a recent EPC model - 1800 444 224
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