Club Car 1998 DS, Maintenance And Service Manual Supplement

Page: 94 / 132

POWERDRIVE BATTERY CHARGER Charger Repairs
Page 14-22 1998/1999 PowerDrive Plus Maintenance and Service Supplement
14
4. Connect the other secondary transformer lead (tan) to the top 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) .
5. Replace charger cover and check charger for proper operation.
TRANSFORMER
Transformer Removal
1. Remove the charger cover. See preceding WARNING.
2. Disconnect tan primary coil lead from the charger relay, then disconnect the tan primary coil lead from the white
wire in the AC cord (Figures 14-4 and 14-5, Pages 14-7 and 14-8) .
3. Disconnect the two tan secondary transformer leads from the heat sink assembly (Figures 14-4 and 14-5,
Pages 14-7 and 14-8) .
4. Disconnect the two black secondary transformer leads from the fuse assembly (Figures 14-4 and 14-5,
Pages 14-7 and 14-8) .
5. Remove four bolts and nuts mounting transformer to case and remove transformer (Figures 14-4 and 14-5, Pages
14-7 and 14-8) .
Transformer Installation
1. Install the transformer with the secondary coil to the rear of the charger case. Tighten the four bolts and nuts
to 28 in.lb (3.2 N-m) (Figures 14-4 and 14-5, Pages 14-7 and 14-8) .
2. Connect one secondary transformer lead (tan) to the top terminal post of the heat sink assembly (Figures 14-
4 and 14-5, Pages 14-7 and 14-8) . Tighten nut to 18 in.lb (2.0 N-m).
3. Connect the other secondary transformer lead (tan) to the bottom terminal post of the heat sink assembly
(Figures 14-4 and 14-5, Pages 14-7 and 14-8) . Tighten nut to 18 in.lb (2.0 N-m).
4. Connect one secondary transformer lead (black) to one terminal of the fuse assembly (Figures 14-4 and 14-
5, Pages 14-7 and 14-8) . Tighten nut to 22 in.lb (2.5 N-m).
5. Connect the other secondary transformer lead (black) to the remaining terminal of the fuse assembly (Fig-
ures 14-4 and 14-5, Pages 14-7 and 14-8) . Tighten nut to 22 in.lb (2.5 N-m).
6. Connect the tan primary lead to the charger relay (Figures 14-4 and 14-5, Pages 14-7 and 14-8) .
7. Connect other tan primary lead to white wire from AC cord (Figures 14-4 and 14-5, Pages 14-7 and 14-8) .
8. Replace charger cover and check charger for proper operation.
AMMETER
Ammeter Removal
1. Remove charger cover. See preceding WARNING.
2. Disconnect black wire from DC cord (5), and bus bar (3) from ammeter (Figure 14-20, Page 14-23) .
3. Remove the two nuts (2) that secure the ammeter to the charger face (Figure 14-20, Page 14-23) .
4. Remove the ammeter from the face of the charger.
Ammeter Installation
1. Place the ammeter in position in the charger face (Figure 14-20, Page 14-23) .
2. Install the nuts (2) and tighten until ammeter is firmly secured (Figure 14-20, Page 14-23) .
3. Connect the black wire of the DC cord (5) to the left (as viewed from inside the charger) post of the ammeter
(Figure 14-20, Page 14-23) .
4. Connect the bus bar (3) from the fuse link to the right post of the ammeter. Place flat washers on both sides of
the bus bar (Figure 14-20, Page 14-23) .
5. Thread nuts onto both posts of the ammeter until just past finger tight. While holding the outside nut, turn
the inside nut counterclockwise 1/4 turn (Figure 14-20, Page 14-23) . See following CAUTION.