Club Car 1996 DS Golf Car Gasoline, Service Manual

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Page 23-38
23B
E
Test Procedures, Continued:
TEST PROCEDURE 1
Battery Voltage Too Low or Bad Connection Between Plug and Receptacle:
1. Check the DC plug and receptacle for damage, dirt, corrosion, or any condition that might prevent a
good electrical connection.
2. Inspect the receptacle contacts to insure that they are not damaged and that they are firmly seated
within the receptacle.
3. Check the wire connections to the charger receptacle:
3.1. Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of
battery No. 1.
3.2. Make sure that the two nuts that secure the two 10 gauge black wires to the receptacle fuse
assembly are tight.
3.3. Check the connections of the 10 or 18 gauge grey wire from the receptacle to the sense lead
fuse, and from the sense lead fuse to the on-board computer wire harness (Figure 23-24).
3.4. Remove the grey sense lead fuse assembly and check its continuity with an multimeter set to
ohms (
Ω
). The resistance should be less than 2 ohms.
4. Measure the voltage of the battery pack between the positive post of battery No. 1 and the negative
post of battery No. 6; normal no-load voltage will be 50 to 52 volts for fully charged batteries. The volt-
age of the battery pack must be over 36 volts DC in order to allow the on-board computer to close the
charger relay (Figure 23-25). If battery pack voltage is too low to start charger, see Charging Battery
Pack With Low Voltage, Section 22, Page 22-18.
TEST PROCEDURE 2
On-Board Computer:
1. Check the circuit breaker on the front of the charger and reset if necessary.
2. Select a charger that is normally connected to another vehicle and that is known to operate properly.
Leave the AC cord of the selected test charger connected to the AC outlet that it normally is connected
to. This will insure that AC power is present.
3. Plug the DC cord from the selected test charger into the receptacle of the vehicle that is not charging
properly.
4. If the test charger fails in the same manner as the charger normally used with the vehicle, then the
vehicle charging circuit is not functioning properly (See Page 23-34, or Section 20, Page 20-5).
• 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 UNPLUG THE ELECTRICAL CORDS BEFORE ATTEMPTING ANY REPAIRS TO THE
CHARGER. FIRST UNPLUG THE AC CORD FROM THE OUTLET AND THEN UNPLUG THE DC
CORD FROM THE VEHICLE.
• DO NOT BY-PASS THE SENSE LEAD FUSE!
WARNING
WARNING