Club Car 1996 DS Golf Car Gasoline, Service Manual

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Page 23-21
E
23A
3. Remove the four screws (1) from the bezel (2).
4. Remove the four screws (3 and 1) attaching the receptacle to the fuse link bracket (4).
Installing the New Receptacle (Figure 23-16)
1. Install the four screws (1 and 3) which attach the receptacle (13) to the fuse link bracket (4). Tighten the
screws to 15-25 in.lbs. (1.7/2.8 N-m ).
2. Install the red wire of the fuse link to the positive (+) terminal of the receptacle (the positive (+) and neg-
ative (-) terminals are labeled on the face of the receptacle). Tighten nut to 20-25 in.lbs. (2.0/3.0 N-m).
3. Install the small black wire (from the wiper switch) and the white wire (from the negative battery post)
on the negative (-) terminal of the receptacle. Tighten the nut to 20-25 in.lbs. (2.0/3.0 N-m).
4. Position the bezel (2) and fuse link bracket (4) and install the four mounting screws (1) through the
bezel and into the fuse link bracket. Tighten the screws to 15-25 in.lbs. (1.7/2.8 N-m).
ON-BOARD RECEPTACLE FUSE LINK
If the receptacle fuse link is blown, the vehicle cannot be charged until the fuse has been replaced. The fuse
link is located on fuse link bracket in the battery compartment (rear portion of the charger receptacle) (See
Figure 23-4, Page 23-3).
Receptacle Fuse Link Disassembly (Figure 23-16)
1. Remove the two screws (5) and then the lens (6).
2. Remove the outer nuts (12), lockwashers (16), and wires (9, 10, and 11).
3. Remove the remaining nuts (8).
4. Remove the fuse link (7) from the base (17).
Receptacle Fuse Link Assembly (Figure 23-16)
1. Install a new fuse link (7) (Club Car Part No. 1012085) into the base (17).
2. Install the nuts (8) which attach the fuse link to the base and tighten them to 15-20 in.lbs. (1.7/2.0 N-m).
3. Connect the red wire (9) (from the forward and reverse switch) and the orange wire (10) (from the
reverse buzzer) to the passenger side of the fuse assembly and install the lock washer (16) and outer
nut (12). Tighten the nut to 20-25 in.lbs. (2.0/3.0 N-m) (Figure 23-16) (See Figure 23-4, Page 23-3).
4. Connect the red wire (11) (from the charger receptacle) to the driver’s side of the fuse assembly and
install the lock washer (16) and nut (12). Tighten the nut to 20-25 in.lbs. (2.0/3.0 N-m).
5. Install the fuse link assembly and cover (6). Tighten the screws to 15-25 in.lbs. (1.7/3.0 N-m).
• MAKE SURE THAT THE BLACK AND WHITE WIRES DO NOT TOUCH.
.
• UNDER NORMAL OPERATING CONDITIONS, THE RECEPTACLE FUSE LINK SHOULD NEVER
BLOW UNLESS THERE IS AN ELECTRICAL PROBLEM. IF THE FUSE BLOWS, DETERMINE THE
CAUSE OF THE PROBLEM AND CORRECT IT. THEN REPLACE THE FUSE.
• ALWAYS WEAR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE.
WARNING
WARNING