Transformer - Club Car 2008-2011 Maintenance And Service Manual

7
POWERDRIVE 3 – MODEL 26580

TRANSFORMER

See General Warning, Section 1, Page 1-1. See additional WARNING on page 7-1.
Transformer Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Disconnect the black primary coil wire (5) from the charger relay (Figure 7-22, Page 7-25).
4. Carefully cut the heatshrink (7) that insulates the AC cord white wire (4) where it connects to the tan pri-
mary coil wire.
5. Disconnect the AC cord white wire (4) from the primary coil tan wire.
6. If equipped, remove wire tie(s) securing transformer wires.
7. Note wire locations for reassembly and then disconnect the orange and purple secondary coil trans-
former wires (1 and 2) from each diode (Figure 7-9, Page 7-11).
8. Remove the four screws that secure the transformer to the mounting brackets and remove the trans-
former.
Transformer Installation
1. Install the transformer with primary coil to the rear of the charger case. Secure the transformer to the
mounting brackets with four screws.
2. Connect the orange and purple secondary coil transformer wires (1 and 2) to the diodes at the original
locations (Figure 7-9, Page 7-11).
3. Connect the black transformer primary coil wire (5) to the charger relay (Figure 7-22, Page 7-25).
4. Place a piece of heatshrink tubing over the AC cord white wire.
5. Connect the AC cord white wire (4) to the tan primary coil wire (Figure 7-22, Page 7-25).
6. Slide the heatshrink tubing (7) over the connection and apply heat to the heatshrink to insulate the con-
nection between the AC cord white wire and the tan primary coil wire. See following WARNING.
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WARNING
• Make sure the electrical connections are properly insulated. Failure to properly insulate
electrical connections in the charger could result in a short circuit.
7. If equipped, replace wire tie(s) securing transformer wires. See following WARNING.
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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.
8. Install the charger cover and check charger for proper operation.
Page 7-30 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charger Repairs