Retractable Ac Cord Reel - Club Car 2008-2011 Maintenance And Service Manual

9
IQ PLUS CHARGER (ONBOARD)
3. Disconnect the AC cord black wire from the AC circuit breaker (Figure 9-19, Page 9-27).
4. Disconnect the AC cord white wire from the control board.
5. Disconnect the AC cord green wire from the charger base (Figure 9-19, Page 9-27).
6. Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger.
Short AC Cord Installation
1. Insert the black, white, and green leads of the new AC cord into the charger through the hole in the
charger face (Figure 9-19, Page 9-27).
2. Connect the black wire to the AC circuit breaker, the white wire to the control board, and the green wire
to the charger base (Figure 9-3, Page 9-6). Tighten the screw on the green (ground) wire terminal to 18
in-lb (2.0 N·m).
3. Position the strain relief bushing on the AC cord.
4. Using pliers, install the strain relief bushing and AC cord into the mounting hole in the charger face.
5. Install the charger cover and install the charger in the vehicle. See Onboard Charger Installation on
page 9-31.
6. Check charger for proper operation.

RETRACTABLE AC CORD REEL

See General Warning, Section 1, Page 1-1.
Retractable AC Cord Reel Removal
1. Disconnect retractable AC cord from AC outlet. See Onboard Charger Removal on page 9-31. See
WARNING on page 9-22.
2. Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord
reel by gently cutting the heatshrink tubing (Figure 9-13, Page 9-18).
3. Disconnect the short AC cord from the retractable cord reel.
4. Carryall 2/252, Turf 2/252, XRT 900, Carryall 6 and Transporter 4 and 6: Remove four screws (1)
securing the cord reel housing (2), and its backing plate (3), to vehicle (Figure 9-20, Page 9-29).
5. Remove hardware securing U-shaped bracket (4) of retractable cord reel assembly (5).
5.1. Villager 6 and 8: Remove four screws (6) securing U-shaped bracket to charger.
5.2. Carryall 2/252, Turf 2/252, XRT 900, Carryall 6 and Transporter 4 and 6: Remove four bolts (7)
and locknuts (8) securing U-shaped bracket to vehicle (9).
6. Lift retractable cord reel assembly from vehicle.
Retractable AC Cord Reel Installation
1. Install in reverse order of removal.
2. Install and tighten U-shaped bracket hardware securing retractable cord reel assembly.
2.1. Villager 6 and 8: Tighten four screws (6) to 13 in-lb (1.5 N·m).
2.2. Carryall 2/252, Turf 2/252, XRT 900, Carryall 6 and Transporter 4 and 6: Tighten four bolts (7)
and locknuts (8) to 65 in-lb (7.3 N·m).
3. Carryall 2/252, Turf 2/252, XRT 900, Carryall 6 and Transporter 4 and 6: Tighten four screws (1),
securing the cord reel housing (2), and its backing plate (3), to 16 in-lb (1.8 N·m).
4. Place new heatshrink tubing over the short AC cord and connect the short AC cord to the retractable cord
reel. Slide the tubing over the connection and carefully apply heat to shrink it.
Page 9-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charger Repairs