Onboard Charger Removal And Installation - Club Car 2008-2011 Maintenance And Service Manual

IQ PLUS CHARGER (ONBOARD)

ONBOARD CHARGER REMOVAL AND INSTALLATION

See General Warning, Section 1, Page 1-1.
ý
WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 9-3, Page 9-6).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and
remove the battery charger from the vehicle. See Onboard Charger Removal on page 9-31.
Onboard Charger Removal
1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 1-3.
2. Disconnect the charger DC cord at the three pin connector (1) (Figure 9-22, Page 9-32).
3. For Carryall 2/252 and 6, Turf 2/252, XRT 900 and Transporter 4 and 6 vehicles: Carefully remove
the heatshrink tubing from the AC cord connection and disconnect the short AC cord from the retractable
cord reel (Figure 9-13, Page 9-18).
4. Remove hardware securing charger to chassis.
4.1. Villager 6 and 8: Remove four bolts (2), flat washers (3), lock washers (4) and nuts (5) from charger
mounting plates.
4.2. Carryall 2/252, Turf 2/252 and XRT 900: Remove two bolts (2) from topside of charger mounting
plate.
4.3. Carryall 6 and Transporter 4 and 6: Remove two nuts (5) from underside of charger mounting
plate.
5. Lift charger assembly from vehicle.
Onboard Charger Installation
1. Installation is reverse of removal.
2. Install and tighten hardware securing charger to chassis.
2.1. Villager 6 and 8: Tighten four bolts (2) and nuts (5) to 108 in-lb (12 N·m).
2.2. Carryall 2/252, Turf 2/252 and XRT 900: Tighten two bolts (2) to 108 in-lb (12 N·m).
2.3. Carryall 6 and Transporter 4 and 6: Tighten two nuts (5) to 108 in-lb (12 N·m).
3. For Carryall 2/252 and 6, Turf 2/252, XRT 900 and Transporter 4 and 6 vehicles: Place new heat-
shrink tubing (6) (CC P/N 1017189) over the short AC cord and connect the short AC cord to the retract-
able cord reel (Figure 9-22, Page 9-32). Slide the tubing over the connection and carefully apply heat
to shrink it.
4. Connect the batteries. See Connecting The Batteries on page 1-4.
2008-2011 Domestic Battery Charger Maintenance and Service Manual
Onboard Charger Removal and Installation
9
Page 9-31