Transformer - Club Car 2008-2011 Maintenance And Service Manual

IQ PLUS CHARGER (EXTERNAL)
4. Connect the other secondary coil transformer wire (tan) to the top terminal post of the heatsink. Tighten
nut to 18 in-lb (2.0 N·m).
5. Install the charger cover and check charger for proper operation.

TRANSFORMER

See General Warning, Section 1, Page 1-1. See additional WARNING on page 8-1.
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 tan primary coil wire from the charger relay (Figure 8-5, Page 8-9 and Figure 8-6,
Page 8-12).
4. Disconnect the AC cord white wire from the primary coil tan wire.
5. Remove the wire tie that secures the DC cord wire to the secondary coil wire (tan).
6. Disconnect the two tan secondary coil transformer wires from the heatsink (Figure 8-5, Page 8-9 and
Figure 8-6, Page 8-12).
7. Disconnect the two black secondary coil transformer wires from the fuse.
8. Remove the four bolts and nuts that mount the transformer to the case and remove the transformer.
Transformer Installation
1. Install the transformer with secondary coil to the rear of the charger case. Tighten the four bolts and nuts
to 28 in-lb (3.2 N·m) (Figure 8-6, Page 8-12).
2. Connect one secondary coil transformer wire (black) to one terminal of the fuse. Tighten nut to 22 in-lb
(2.5 N·m).
3. Connect the other secondary coil transformer wire (black) to the remaining terminal of the fuse. Tighten
nut to 22 in-lb (2.5 N·m).
4. Connect one secondary coil transformer wire (tan) to the top terminal post of the heatsink. Tighten nut
to 18 in-lb (2.0 N·m).
5. Connect the other secondary coil transformer wire (tan) to the bottom terminal post of the heatsink.
Tighten nut to 18 in-lb (2.0 N·m).
6. Connect the tan primary coil transformer wire to the charger relay.
7. Connect the other tan primary coil transformer wire to the white wire from the AC cord.
8. 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.
9. Install the charger cover and check charger for proper operation.
2008-2011 Domestic Battery Charger Maintenance and Service Manual
8
Charger Repairs
Page 8-25