Heatsink - Club Car 2008-2011 Maintenance And Service Manual

3
POWERDRIVE CHARGER (EXTERNAL)
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 center terminal of the heatsink and tighten the nut to 18
in-lb (2.0 N·m) (Figure 3-24, Page 3-27).
3. Attach the blue wire of the new DC cord to the red wire assembly at the charger relay (Figure 3-24,
Page 3-27).
4. Attach black wire (4) of the new DC cord to ammeter. Install nut (1) onto post of ammeter slightly more
than finger tight. While holding the inside nut (2), tighten the outside nut (1) 1/4 turn (Figure 3-25,
Page 3-27). See following CAUTION.
CAUT ION
• Do not allow ammeter post to rotate as the nut is tightened. Rotation of the post could result
in a damaged ammeter.
5. Using pliers, put the strain relief bushing on the cord and insert it into the charger base.
6. Tie the wires together as they were before the wire tie was removed. 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.
7. 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).

HEATSINK

See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
Heatsink Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Remove both secondary coil transformer wires (tan) from the heatsink (Figure 3-9, Page 3-11 and
Figure 3-10, Page 3-15).
4. Remove the two red wires from the heatsink.
5. Remove the nuts and bolts that secure the heatsink to the case.
Heatsink Installation
1. Place heatsink against charger base. Make sure clear plastic insulator sheet is between the heatsink and
the charger base. Install the nuts and bolts that secure the heatsink to the case. Tighten the bolts to 18
in-lb (2.0 N·m) (Figure 3-9, Page 3-11 and Figure 3-10, Page 3-15).
2. Connect the red wire from the DC cord and the red wire from the charger relay to the center terminal post
on the heatsink. Tighten nut to 18 in-lb (2.0 N·m).
Page 3-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charger Repairs