Charger Repairs; Heat Sink Assembly - Club Car 1998 Maintenance And Service Manual Supplement

POWERDRIVE BATTERY CHARGER
5. Remove the terminal on the blue charger DC cord lead at the relay (Figure 14-18, Page 14-20).
6. Using pliers, squeeze the strain relief bushing and remove the cord set (Figure 14-18, Page 14-20).
Charger Cord and Plug Installation
1. Insert the leads of the new cord through the hole in the charger base.
2. Attach the red lead of the new cord set to the center terminal of the heat sink and tighten the nut to 14 in.lb
(1.6 N-m) (Figure 14-18, Page 14-20).
3. Attach the blue lead of new cord set to the charger relay (coil) terminal (Figure 14-18, Page 14-20).
4. Attach the black lead of the new cord to the ammeter. Install nut (1) onto post of ammeter slightly more than
finger tight. While holding the outside nut (1), turn the inside nut (2) counterclockwise 1/4 turn (Figure 14-
19, Page 14-20). See following CAUTION.
CAUTION
• DO NOT ALLOW AMMETER POST TO ROTATE AS THE NUT IS TIGHTENED. IF IT IS ALLOWED TO ROTATE, THE
AMMETER COULD BE DAMAGED.
5. Using pliers, put the strain relief bushing on the cord and insert into the charger base.
6. Position the charger cover on the base. Install the attachment screws, starting with the bottom holes. Tighten
the screws to 11 in.lb (1.2 N-m).

CHARGER REPAIRS

Read DANGER and WARNING on page 14-1.
WARNING
• ALWAYS DISCONNECT THE ELECTRICAL CORDS BEFORE ATTEMPTING ANY TESTS OR REPAIRS TO THE CHARGER.
FIRST DISCONNECT THE AC CORD FROM THE AC OUTLET AND THEN DISCONNECT THE DC CORD FROM THE
VEHICLE.

HEAT SINK ASSEMBLY

Heat Sink Assembly Removal
1. Remove charger cover. See preceding WARNING.
2. Remove both secondary transformer leads (tan) from the heat sink assembly (Figures 14-4 and 14-5, Pages
14-7 and 14-8).
3. Remove the two red wires from the heat sink assembly (Figures 14-4 and 14-5, Pages 14-7 and 14-8).
4. Remove the nuts and bolts that secure the heat sink assembly to the case.
Heat Sink Assembly Installation
1. Place heat sink against charger base. Make sure clear plastic insulator sheet is between the heat sink and the
charger base. Install the nuts and bolts that secure the heat sink assembly to the case. Tighten the bolts to 22
in.lb (2.4 N-m) (Figures 14-4 and 14-5, Pages 14-7 and 14-8).
2. Connect the red wire from the DC cord and the red wire from the charger relay to the center terminal post on the
heat sink assembly. Tighten nut to 18 in.lb (2.0 N-m) (Figures 14-4 and 14-5, Pages 14-7 and 14-8).
3. Connect one of the secondary transformer leads (tan) to the bottom terminal post of the heat sink assembly.
Tighten nut to 18 in.lb (2.0 N-m) (Figures 14-4 and 14-5, Pages 14-7 and 14-8).
1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-21
14
Charger Repairs