Club Car 2008-2011 Maintenance And Service Manual page 79

POWERDRIVE CHARGER (ONBOARD)
8. Ensure that the charger is wired properly and all connections are clean and tight. See following CAU-
TION.
CAUT ION
• If connections are not clean and tight, excessive heat will be created and the charger may
become damaged.
Figure 4-13 Diode Test
Test Procedure 4B – Both Diodes Failed
See General Warning, Section 1, Page 1-1.
To check the diodes, use Test Procedure 4A – Single Diode Failure on page 4-14. If both diodes have failed
closed, both charger fuse links will be blown. If both diodes have failed open, the relay will close and the trans-
former will hum, but the ammeter will not indicate any output and the AC circuit breaker may trip off. If both
diodes have failed open or closed, the entire heatsink must be replaced. To determine why both diodes failed:
1. Check the batteries and the receptacle to ensure that they are wired in the correct polarity. (Figure 4-2,
Page 4-3).
2. Make sure the charger is wired correctly: The DC cord red wire should be connected to the center ter-
minal of the heatsink, the DC cord blue wire should be connected to the control board, and the DC cord
black wire should be connected to the left side of the ammeter (when viewed from inside the charger)
(Figure 4-4, Page 4-6). If a reverse polarity connection is made between the charger and the batteries,
both fuse links will blow when the DC cord is connected to the vehicle, whether or not the AC cord is
plugged into an outlet.
3. Make sure the charger is wired to the vehicle correctly; the DC cord red wire should be connected to the
same large post as the 6-gauge red wire connected to the positive (+) post of battery no. 1. The DC cord
blue wire should be connected to the sense lead fuse. The DC cord black wire should be connected to
the terminal block located on the vehicle component mounting plate (Figure 4-2, Page 4-3). If a reverse
polarity connection is made between the charger and the batteries, both fuse links will blow when the DC
cord is connected to the vehicle, whether or not the AC cord is plugged into an outlet.
4. On rare occasions, both diodes may fail as a result of a lightning strike at the charging location.
5. Excessive heat due to a loose connection may also cause both fuse links to blow. Be sure fuse connec-
tions are tightened to 22 in-lb (2.5 N·m).
6. Ensure that the charger and vehicle are wired properly and all connections are clean and tight.
DISCONNECTED
SECONDARY
COIL WIRE
2008-2011 Domestic Battery Charger Maintenance and Service Manual
Figure 4-14 Diode Test – Probes Reversed
4
Test Procedures
Page 4-15