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

IQ PLUS CHARGER (EXTERNAL)

CHARGER REPAIRS

See General Warning, Section 1, Page 1-1. See additional WARNING on page 8-1.
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WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 8-5, Page 8-9).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and
the DC plug from the vehicle charger receptacle.

DC CORD

See General Warning, Section 1, Page 1-1. See additional WARNING on page 8-1.
DC Cord Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
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 8-17, Page 8-23).
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 red wire assembly that connects to the charger relay
(Figure 8-16, Page 8-23).
8. Using pliers, squeeze the strain relief bushing and remove the DC cord (Figure 8-16, Page 8-23).
DC CORD
BLACK WIRE
TO AMMETER
RED WIRE
TO HEATSINK
STRAIN RELIEF
BUSHING
Figure 8-16 DC Cord
DC CORD BLUE WIRE
TO RED WIRE ASSEMBLY
AT RELAY
DC CORD
2008-2011 Domestic Battery Charger Maintenance and Service Manual
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4
6
Figure 8-17 DC Cord Replacement
8
Charger Repairs
2
3
Page 8-23