Transformer; Ammeter - Club Car 2008-2011 Maintenance And Service Manual

9
IQ PLUS CHARGER (ONBOARD)

TRANSFORMER

See General Warning, Section 1, Page 1-1.
Transformer Removal
1. Disconnect the AC cord and remove the battery charger from the vehicle. See Onboard Charger
Removal on page 9-31. See WARNING on page 9-22.
2. Remove the charger cover.
3. Disconnect the black primary coil wire from the charger relay (Figure 9-3, Page 9-6).
4. Disconnect the tan primary coil wire from the control board.
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 9-3, Page 9-6).
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 9-3, Page 9-6).
2. 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).
3. 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).
4. Connect one secondary coil transformer wire (black) to one terminal of the fuse assembly. Tighten nut
to 22 in-lb (2.5 N·m).
5. Connect the other secondary coil transformer wire (black) to the remaining terminal of the fuse assembly.
Tighten nut to 22 in-lb (2.5 N·m).
6. Connect the black primary coil transformer wire to the charger relay.
7. Connect the other primary coil transformer wire to the control board.
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 install the charger in the vehicle. See Onboard Charger Installation on
page 9-31.
10. Check charger for proper operation.

AMMETER

See General Warning, Section 1, Page 1-1.
Ammeter Removal
1. Disconnect the AC cord and remove the battery charger from the vehicle. See Onboard Charger
Removal on page 9-31. See WARNING on page 9-22.
Page 9-24 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charger Repairs