Club Car Gasoline Service Manual page 491

Removing the DC Cord
1. Unplug the AC and DC cords.
2. Remove the charger cover.
DANGER
• HIGH VOLTAGE! WITH THE CHARGER ON, THE VOLTAGE OF THE CAPACITOR INSIDE THE
CHARGER IS APPROXIMATELY 650 VOLTS. USE EXTREME CAUTION WHEN WORKING
NEAR CAPACITOR TERMINALS.
3. Disconnect the black lead of the DC cord from the ammeter by loosening the nut. Support the terminal
as the nut is loosened to prevent rotation of the connection. Leave the black wire from the electronic
timer on the terminal post.
4. Remove the nut that retains the white lead of the DC cord on the heat sink assembly. Leave the red
wire from the electronic timer on the screw at the heat sink assembly.
5. Using pliers, squeeze the strain relief bushing and remove the cord set.
5
1
Installing the New DC Cord
1. Insert the leads of the new cord through the hole in the charger base.
2. Make sure the red wire of the electronic timer is on the middle terminal of the heat sink assembly, then
place the white lead of the new cord on the terminal and tighten the nut to 12-15 in.lbs. (1.4/1.7 N-m).
3. Make sure the black wire (4) of the electronic timer is on the ammeter post. Attach the black lead (5) of
the new cord and start the nut on the post until finger tight (Figure 23-15)
CAUTION
• IN STEP 4 (NEXT PAGE), DO NOT ALLOW AMMETER POST TO ROTATE AS NUT IS TIGHT-
ENED. IF IT ROTATES, THE AMMETER COULD BE DAMAGED.
4
FIGURE 23-15
2
3
.
23A
E
Page 23-19