Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 494 / 544

Page 23-22
23A
E
CHARGER REPAIRS
ELECTRONIC TIMER KIT
Removing the Electronic Timer Kit
1. Remove the two screws attaching the electronic timer assembly to the face of the charger.
2. Slide the electronic timer assembly from the charger and carefully remove the control cable connector
from the timer.
Installing a New Electronic Timer Kit
1. Carefully connect the control cable connector to the new timer and slide the timer assembly into the
charger.
2. Install the two timer assembly retaining screws in the face of the charger.
Electronic Timer Relay Wiring
If the wires from the relay were disconnected, connect them to the numbered relay terminals as follows:
1. Attach the orange wire to terminal No. 6.
2. Attach the brown wire to terminal No. 1.
3. Attach the black wire from the AC cord to terminal No. 3.
4. Attach the black extension wire from the transformer primary coil to terminal No. 5.
Checking Proper Operation of Electronic Timer Kit
1. With the DC plug disconnected from the receptacle, plug the AC cord into an outlet. The relay on the
electronic timer kit should not close. A multimeter set to DC volts and connected across the DC plug
should indicate zero volts. No transformer hum should be heard.
2. Unplug the AC cord from its outlet and connect the DC plug to the receptacle. The relay on the elec-
tronic timer kit should close with an audible “click” after a two to five second delay.
3. If the electronic timer kit does not operate as in step one or two above, refer to the wiring diagram (Fig-
ure 23-2, Page 23-2) and make sure that the charger is wired correctly. If the electronic timer kit oper-
ates properly, the charger is ready for use. Always monitor the first charge cycle to verify the charger is
turning off properly.
• 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.
.
• MAKE SURE THAT ALL CONNECTIONS ARE CLEAN AND TIGHT. ALSO MAKE SURE THAT ALL
WIRES AND TERMINALS ARE POSITIONED SO THAT THEY DO NOT SHORT TOGETHER OR
TO THE CHARGER BASE.
WARNING
WARNING