Diode/Heatsink - Club Car 2008-2011 Maintenance And Service Manual

POWERDRIVE 3 – MODEL 26580
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 ammeter (Figure 7-23, Page 7-28).
3. Attach the blue wire of the new DC cord to the relay board assembly.
4. Attach black wire of the new DC cord to fuse. Install the nut onto post of the fuse and tighten to 23 in-lb
(2.6 N·m). 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.
5. Using pliers, put the strain relief bushing on the cord and insert it into the charger base.
6. 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).

DIODE/HEATSINK

NOTE: This Powerdrive 3 Model 26580 uses two diode/heatsink assemblies. A running change installed
these two diode/heatsink assemblies in place of a rectifier mounted to an aluminum heat sink plate.
The model number with the rectifier was 26560. See Section 6 – PowerDrive 3 – Model 26560.
Diode/Heatsink Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Note wire locations for reassembly and then disconnect the orange and purple secondary coil trans-
former wires (1 and 2) from the diode/heatsink being replaced (Figure 7-9, Page 7-11 and Figure 7-10,
Page 7-15).
4. Remove the white wire from the side diode/heatsink or the brown wire from the top diode/heatsink
depending on which diode/heatsink is being replaced.
5. Remove the nuts and bolts that secure the diode/heatsink to the case.
Diode/Heatsink Installation
1. Place diode/heatsink against charger base. Make sure clear plastic insulator sheet is between the diode/
heatsink and the charger base. Install the nuts and bolts that secure the diode/heatsink to the case.
Tighten the bolts to 18 in-lb (2.0 N·m) (Figure 7-9, Page 7-11 and Figure 7-10, Page 7-15).
2. Connect the white wire from the ammeter to the center terminal post on the side diode/heatsink or the
brown wire from the fuse link to the center terminal post on the top diode/heatsink. Tighten nut to 18 in-
lb (2.0 N·m).
3. Connect the orange and purple secondary coil transformer wires (1 and 2) to the diode/heatsink at the
original locations. Tighten nuts to 18 in-lb (2.0 N·m).
4. Install the charger cover and check charger for proper operation.
2008-2011 Domestic Battery Charger Maintenance and Service Manual
7
Charger Repairs
Page 7-29