Club Car 1995 Golf Car, Maintenance Service Supplement

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Test Procedure 4, Continued:
PROCEDURE 4A - SINGLE DIODE FAILURE:
A single diode failure is indicated by one fuse link blowing (closed circuit diode) or by the charger output being
low (open circuit diode). If a diode has failed, the entire rectifier assembly must be replaced. To check diodes:
1. Unplug the AC cord from its outlet and the DC plug from the receptacle, then remove the charger cover.
2. Disconnect one transformer secondary coil lead from the diode terminal (Figure 19-9).
3. Using a low voltage continuity tester, connect the red (+) tester lead to the diode mounting plate and the
other tester lead to a diode terminal and note the reading (Figure 19-9).
4. Reverse the tester leads and check each diode again and note the reading (Figure 19-10). A diode is
designed to conduct current in one direction only; if a diode conducts current (shows continuity) in both
directions, the complete rectifier assembly with diodes must be replaced. If a diode does not conduct
current (does not show continuity) in either direction, the complete rectifier assembly must be replaced.
5. On rare occasions, a single fuse link may melt due to excessive heat. This can be caused by a loose
internal fuse connection. Check all three fuse connections inside the charger to be sure that they are
clean and tight. The proper torque on the fuse link connections is 20 in.lbs. (2.2 N-m).
6. Be sure that the charger is wired properly and that all connections are clean and tight.
PROCEDURE 4B - BOTH DIODES FAILED:
To check the diodes, use the diode test procedure 4A. If both diodes have failed closed, both charger links
will be blown. If both diodes have failed open, the relay will close and the transformer will hum, but the amme-
ter will indicate that there is no output. If both diodes have failed open or closed, the entire rectifier assem-
bly must be replaced. The following steps should be used to determine why both diodes failed:
1. Check the batteries and the receptacle to be sure that they are wired in the correct polarity. Also check
the voltage and polarity at the receptacle.
WARNING
• IF CONNECTIONS ARE NOT CLEAN AND TIGHT, EXCESSIVE HEAT WILL BE CREATED
AND THE CHARGER COULD BE DAMAGED.
19-16
DISCONNECT
SECONDARY
COIL LEAD
REVERSE POSITIONS
OF VOM LEADS
FIGURE 19-9
FIGURE 19-10