Charger Repairs; Dc Cord - Club Car 2008-2011 Maintenance And Service Manual

4
POWERDRIVE CHARGER (ONBOARD)
4. Place the continuity test probe on the two terminals of the AC circuit breaker. The tester should indicate
continuity. If the tester does not indicate continuity, replace the AC circuit breaker.

CHARGER REPAIRS

See General Warning, Section 1, Page 1-1.
ý
WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 4-4, Page 4-6).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet,
disconnect the DC cord from the vehicle, and remove the battery charger from the vehicle.
See Onboard Charger Removal on page 4-33.

DC CORD

DC Cord Removal
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 DC cord black wire (4) from the ammeter by loosening the nut (1). Support the terminal as
the nut is loosened to prevent rotation of the connection (Figure 4-23, Page 4-24).
4. Remove nut attaching the red wire (6) of the charger DC cord to the heatsink.
5. Remove the wire tie that secures the DC cord wire to the secondary coil wire (tan).
6. Remove the wire tie on the DC cord near the strain relief bushing.
7. Disconnect the DC cord blue wire from the control board (Figure 4-22, Page 4-24).
8. Using pliers, squeeze the strain relief bushing and remove the DC cord (Figure 4-22, Page 4-24).
DC CORD
BLACK WIRE
TO AMMETER
RED WIRE
TO HEATSINK
STRAIN RELIEF
Figure 4-22 DC Cord
Page 4-24 2008-2011 Domestic Battery Charger Maintenance and Service Manual
DC CORD
BLUE WIRE TO
CONTROL BOARD
DC CORD
BUSHING
1
4
6
Figure 4-23 DC Cord Replacement
Charger Repairs
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