On board charger mounting experiment...

[dannyre]

Unfinished design, but looks good so far.....

My rear flip down has an ice chest built in so I cannot mount it under the seat.....but...

After lots of considerations, I have finally come up with a design that will work for my on board charger mounting.

First you will want to remove the rear body shell and remove your battery ground.

Undo the rear inspection plate located in the rear bag well and locate the shock mounts on the left and right hidden in the rear corners of the open area.

Span two pieces of aluminum angle 17" long from the rear shock mounts all the way to the forward part of the body compartment until it butts against the forward plastic area. The angle on the shock mount end will need one bolt (wont show) to hold it in place while resting. On the forward part of the angle, bolt it thru the plastic area of the rear body (not the body itself), using a short piece of aluminum (which works as a backing plate) from the floor of the outside area of the plastic and drill thru the aluminum backing plate the plastic and into the aluminum angle inside the open area and bolt together. Repeat on other side.

Now you have a solid place to rest the charger shelf, take a piece of 10" X 23 3/4" aluminum and predrill the charger holes for mounting after the shelf is mounted in place. Plenty of clearance above the motor and the battery wires are quite handy...

If mounted facing the rear of the cart, you can cut a small hole in the top area of the inspection plate for viewing status lights if needed. I have not found a good retractable power cord setup I like yet, but one thing at a time....if done right, I may even be able to mount the power cord retractor to the same mount....I'll keep you posted....

I have no idea why the pictures came out sideways, but if someone can fix that, please do....
Attached Thumbnails
Best Charger Option??-charger-mount-2.jpg Best Charger Option??-charger-5.jpg Best Charger Option??-charger-mount-4.jpg Best Charger Option??-charger-mount.jpg

[TahoeDawgZ71]

Looking good.

[dannyre]

It actually worked, and easier than I thought. Basic tools and lots of effort, (and a few minor miscalculations), and it's a done deal. It's solid as a rock and does not interfere with anything... If I can just find a small 12ga cord retractor about 20' to 25', long, Ill be in business. More to come....

[dannyre]

Ordered a 15 amp 12/3 retractable cord today and it should arrive Friday. I have it designed where the male end will exit above the rear wheel hidden under the fender and quite accessible, but not seen. The bolts shown in the last picture are only visible when laying on the ground, not from the sides. Can't wait to start using it....:-)

[jjance]

If this was Facebook.

[Sergio]

Since the AC cable will come out the back of the cart, did You wire the charger into the controller lockout circuit?

[dannyre]

The AC cable will come out from under the drivers side rear fender well, and the OBC will be bypassed.

Not sure about the controller lockout circuit, not familiar with it...please explain...is it part of the OBC?

[Sergio]

The White and the Blue wire splice is a permanent by-pass of the charger interlock safety circuit.

In the IQ and Excell carts, it is pretty simple to continue to use the safety interlock with on-board chargers like the Lester You have.

All You need to add is a 10kΩ - 1 watt resistor:

http://www.mouser.com/ProductDetail/...zOC9bCL9VxU%3d

The resistor gets wired in series with the White wire before the splice with the Blue wire.

The safety interlock wire from the Lester (blue wire) gets wired at the splice between the OBC Blue wire and resistor from the white wire.

That way the cart will not work while the Lester is connected to AC power.

I can post a simple diagram if you need.

[dannyre]

Originally Posted by Sergio

The White and the Blue wire splice is a permanent by-pass of the charger interlock safety circuit.

In the IQ and Excell carts, it is pretty simple to continue to use the safety interlock with on-board chargers like the Lester You have.

All You need to add is a 10kΩ - 1 watt resistor:

http://www.mouser.com/ProductDetail/...zOC9bCL9VxU%3d

The resistor gets wired in series with the White wire before the splice with the Blue wire.

The safety interlock wire from the Lester (blue wire) gets wired at the splice between the OBC Blue wire and resistor from the white wire.

That way the cart will not work while the Lester is connected to AC power.

I can post a simple diagram if you need.

Thanks a ton, and that diagram would be appreciated....l

[scottyb]

This looks like the Lester 4800 like I have?