Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 490 / 544

Page 23-18
23A
E
PLUG AND RECEPTACLE REPLACEMENT
The charger DC cord and plug, and the charger receptacle on the vehicle are wear items that should be
inspected daily. They must be replaced when worn or damaged. If the charger plug and receptacle show
signs of corrosion or are becoming difficult to insert and remove, the receptacle contacts and plug blades can
be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40® brand spray lubricant.
TESTING THE RECEPTACLE
1. Inspect the receptacle for cracks, loose connections and frayed wiring.
2. Insert the tapered end of a test blade (Club Car Part No. 1013930) approximately 1-1/2 inches (38 mm)
into one side of the receptacle, then withdraw the blade from the contact, pulling straight out from the
receptacle.
3. Repeat for the other contact. Both contacts must grip the test blade well enough to create sufficient
pressure (or drag) for an adequate electrical connection. If little or no drag is felt, the receptacle must
be replaced.
CHARGER DC CORD REPLACEMENT
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. ANYONE
DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE
IN GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
WARNINGS STATED IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE OR CHARGER. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• BEFORE ATTEMPTING ANY REPAIRS TO THE CHARGER, ALWAYS UNPLUG THE ELECTRI-
CAL CORDS, FIRST FROM THE AC OUTLET AND THEN FROM THE VEHICLE RECEPTACLE.
• UNPLUG BOTH THE AC AND DC CORDS BEFORE WORKING ON THE CHARGER OR CHANG-
ING CHARGER CORDS.
• DO NOT ROCK OR BEND THE PLUG. TO CONNECT THE CHARGER PLUG TO THE VEHICLE
RECEPTACLE, GRASP THE PLUG (NOT THE CORD) AND PUSH IT STRAIGHT INTO THE
RECEPTACLE.
• TO DISCONNECT THE CHARGER PLUG FROM THE VEHICLE, GRASP THE PLUG (NOT THE
CORD) AND PULL IT STRAIGHT OUT OF THE RECEPTACLE. DO NOT PULL ON THE CORD. DO
NOT TWIST, ROCK, OR BEND THE PLUG SIDEWAYS.
• FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE
CHARGER CORD, THE PLUG, AND(OR) THE VEHICLE RECEPTACLE.
• DO NOT USE THIS CHARGER IF:
- THE PLUG IS TOO LOOSE OR DOES NOT MAKE A GOOD CONNECTION.
- THE PLUG AND/OR RECEPTACLE FEEL HOTTER THAN NORMAL DURING CHARGE.
- THE PLUG BLADES OR RECEPTACLE CONTACTS ARE BENT OR CORRODED.
- THE PLUG, RECEPTACLE, OR CORDS ARE CUT, WORN, HAVE EXPOSED WIRES, OR ARE
DAMAGED IN ANY WAY.
• USING THE CHARGER WITH ANY OF THE ABOVE CONDITIONS COULD RESULT IN A FIRE,
PROPERTY DAMAGE, OR PERSONAL INJURY. REPAIR OR REPLACE WORN OR DAMAGED
PARTS BEFORE USING THE CHARGER.
WARNING
WARNING