Club Car 2007 XRT 800, Maintenance Service Manual

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ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Charger Receptacle
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 23-15
23
CHARGER RECEPTACLE
See General Warning on page 1-1.
The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them
for cracks, loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger
plug or receptacle show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts
and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40®
brand spray lubricant. The plug should then be inserted and removed several times to ensure ease of inser-
tion, ease of removal, and good electrical contact.
Testing the Charger Receptacle
See Test Procedure 12, Section 21, Page 21-28.
See also the appropriate battery charger maintenance and service manual.
Charger Receptacle Inspection
Inspect the receptacle for cracks, loose connections and frayed wiring. See following NOTE.
NOTE: Disassembly of the charger receptacle, for the purpose of removal or installation, is not recom-
mended.
Charger Receptacle Removal
1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-2.
2. Remove the 10-gauge red wire (4) from the positive post of battery no. 1 (Figure 23-14, Page 23-16).
3. Remove black 10-gauge OBC wire (5) from charger receptacle.
4. Disconnect the gray wire (9) from the receptacle at the yellow fuse holder.
5. Remove the four screws (1) that secure the charger receptacle bezel (7) to the receptacle backing plate
(8) and to the vehicle body.
6. Move the receptacle assembly toward the front of the vehicle and tilt receptacle upwards in order for the
receptacle to pass through the hole in the vehicle body.
Charger Receptacle Installation
1. Insert the 10-gauge red wire (4) and the 18-gauge gray wire (3) through the hole in the vehicle body and
the receptacle backing plate (Figure 23-14, Page 23-16) .
2. Insert receptacle into vehicle body.
3. Install the four screws (1) that secure the receptacle to the vehicle body and receptacle backing plate (8).
Tighten screws to 16 in-lb (1.8 N·m).
4. Connect 18-gauge gray wire (9) to yellow fuse holder. Make sure fuse (11) is installed in fuse holder.
5. Connect the 10-gauge black wire (5) to the receptacle fuse link (6) on the charger receptacle
(Figure 23-14, Page 23-16). Tighten to 23 in-lb (2.6 N·m).
6. Connect the 10-gauge red wire (4) to the positive post of battery no. 1.
7. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first.
Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray
(CCI P/N 1014305) to minimize corrosion.