IQ PLUS CHARGER (ONBOARD)
Charger Repairs
Page 9-22
2008-2011 Domestic Battery Charger Maintenance and Service Manual
9
CHARGER REPAIRS
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.
DC CORD
DC Cord Removal
1. Disconnect the AC cord and remove the battery charger from the vehicle.
See Onboard Charger
Removal on page 9-31.
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 9-17, Page 9-22)
.
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 control board
(Figure 9-16, Page 9-22)
.
8. Using pliers, squeeze the strain relief bushing and remove the DC cord
(Figure 9-16, Page 9-22)
.
DC Cord Installation
1. Insert the leads of the new DC cord through the hole in the charger base.
2. Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18
in-lb (2.0 N·m)
(Figure 9-16, Page 9-22)
.
Figure 9-16 DC Cord
Figure 9-17 DC Cord Replacement
RED WIRE
TO HEATSINK
STRAIN RELIEF
BUSHING
DC CORD
DC CORD
BLACK WIRE
TO AMMETER
DC CORD
BLUE WIRE TO
CONTROL BOARD
6
3
2
4
1
Summary of Contents for 2008-2011
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