Club Car 2008-2011 Maintenance And Service Manual page 87

POWERDRIVE CHARGER (ONBOARD)
Transformer
The PowerDrive battery charger transformer has two sets of coils: a primary coil and a secondary coil
(Figure 4-17, Page 4-18).
Primary Coil
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle. See Onboard Charger Removal on page 4-33.
2. Remove the charger cover.
3. Disconnect terminals from transformer (tan) primary coil transformer wires (4 and 6) (Figure 4-17,
Page 4-18).
4. Place the continuity test probes on the disconnected primary transformer coil wires. The tester should
indicate continuity. If tester does not indicate continuity, replace the transformer.
Secondary Coil
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle. See Onboard Charger Removal on page 4-33.
2. Remove the charger cover.
3. Remove the transformer (tan) secondary coil wire (1) from the upper terminal of the heatsink
(Figure 4-17, Page 4-18).
4. Remove the other transformer (tan) secondary coil wire (5) from the bottom terminal of the heatsink and
place the continuity test clip on the ammeter buss bar (7) (Figure 4-17, Page 4-18). Test for continuity
between the buss bar and each of the secondary coil wires (tan). The tester should indicate continuity
between the buss bar and both of the secondary coil wires. If tester does not indicate continuity on both
secondary coil wires, replace transformer. Ensure that the fuse is intact and not blown.
Relay
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle. See Onboard Charger Removal on page 4-33.
2. Remove the charger cover.
3. Remove black wires from contact terminals of the relay (Figure 4-17, Page 4-18). Place continuity test
probes on contact terminals of the relay. The tester should indicate no continuity. If tester indicates con-
tinuity, the relay contacts have failed closed and the relay must be replaced.
Ammeter
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle. See Onboard Charger Removal on page 4-33.
2. Remove the charger cover.
3. Disconnect the black wire from the left ammeter post (as viewed from inside the charger).
4. Place the continuity tester clip on one of the ammeter posts.
5. Place the continuity test probe on the other ammeter post. The tester should indicate continuity. If the
tester does not indicate continuity, replace the ammeter.
AC Circuit Breaker
1. Disconnect the DC cord, the AC cord from the wall outlet, and remove the battery charger from the vehi-
cle. See Onboard Charger Removal on page 4-33.
2. Remove the charger cover.
3. Disconnect the wires from the AC circuit breaker.
2008-2011 Domestic Battery Charger Maintenance and Service Manual
4
Test Procedures
Page 4-23