Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 496 / 544

Page 23-24
23A
E
Installing the Capacitor, Continued:
3. Connect the terminal connectors to the capacitor terminals.
4. Install the charger cover.
5. Check the charger for proper operation.
HEAT SINK ASSEMBLY
Removing the Heat Sink Assembly
1. Remove the charger cover.
2. Disconnect both secondary transformer leads (tan) from the heat sink assembly.
3. Disconnect the red, green, and white wires from the heat sink assembly.
4. Remove the nuts and bolts which secure the heat sink assembly to the case.
Installing the Heat Sink Assembly
1. Position the heat sink assembly and install the nuts and bolts that secure it to the charger case. Tighten
the bolts to 12-15 in.lbs. (1.4/1.7 N-m).
2. Connect the white wire from the DC cord and the red wire of the control cable to the center connector
of the heat sink assembly. Tighten the nut to 12-15 in.lbs. (1.4/1.7 N-m).
3. Connect the green wire of the control cable and one of the secondary transformer leads (tan) to the
bottom connector of the heat sink assembly. Tighten the nut to 12-15 in.lbs. (1.4/1.7 N-m).
4. Connect the other secondary transformer lead (tan) to the top connector of the heat sink assembly.
5. Install the charger cover.
6. Check the charger for proper operation.
TRANSFORMER
Removing the Transformer
1. Remove the charger cover (Figure 23-3, Page 23-2).
2. Disconnect the black extension wire and the transformer primary coil lead, then disconnect the white
wire in the AC cord and the transformer coil lead.
3. Disconnect the secondary transformer leads from the heat sink assembly.
4. Disconnect the secondary transformer leads from the fuse assembly.
• 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.
• HIGH VOLTAGE! WITH THE CHARGER UNPLUGGED AND NOT OPERATING, THE VOLTAGE
OF THE CAPACITOR INSIDE THE CHARGER IS STILL APPROXIMATELY 650 VOLTS. USE
EXTREME CAUTION WHEN WORKING NEAR CAPACITOR TERMINALS.
WARNING
DANGER