Club Car 1995 Golf Car, Maintenance Service Supplement

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Test Procedure 5 Continued:
4. If the circuit shows continuity in both directions, a “short” exists in the charger DC circuit, usually caused
by “shorted” diodes (See Test Procedure 4). If diodes are not “shorted”, check the DC output cord for a
“short” as described in Test Procedure 8.
5. Remove the blue wire from the charger relay and check the continuity between the positive and nega-
tive terminals and the middle pin on the DC plug (Figures 19-4 and 19-5, Page 19-7).
TEST PROCEDURE 6 -
TRANSFORMER:
Failure of the transformer may be caused by natural aging or shorting of adjacent coil turns. If the transformer
has failed, a low or complete lack of output would be observed on the ammeter; however, the transformer
may hum. A blown AC line fuse or circuit breaker in the charger and/or storage facility may have been caused
by a failed transformer. To test the transformer:
1. Disconnect the transformer secondary coil leads No. 1 and No. 5 (Figure 19-13, Page 19-19) from the
diode terminals.
2. In order to apply AC power directly to the transformer primary coil, the relay must be by-passed.
3. Remove the black wire (3) from the circuit breaker and disconnect the tan wire (4) from the relay.
Connect the tan wire to the circuit breaker (Figure 19-13, Page 19-19).
4. Be sure that secondary coil leads are not touching one another. With the relay by-passed, plug the AC
plug into an outlet. If the AC line fuse or circuit breaker blows, the transformer is shorted internally and
must be replaced (Figure 19-13, Page 19-19).
5. If the AC line fuse or circuit breaker does blow, check the transformer secondary voltage across leads
No.1 and No. 5 using a VOM (Club Car Part No. 1011480) . If measured voltages are approximately 85
volts or lower for the secondary coil, the transformer is shorted internally and must be replaced (Figure
19-13, Page 19-19).
6. If the transformer output measurments are 86 volts or higher, disconnect the AC plug from its outlet.
7. If the voltage readings are normal, the transformer is good. Refer to Test Procedure 5 for further tests
of the DC circuit.
DANGER
• DO NOT ALLOW SECONDARY COIL LEADS TO TOUCH ONE ANOTHER. THERE ARE
APPROXIMATELY 120 VOLTS AC PRESENT.
19-18
CAUTION
• ONLY TRAINED TECHNICIANS SHOULD ATTEMPT TO REPAIR OR SERVICE THIS CHARGER.
ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT
PROCEDURES AND HEED THE WARNINGS STATED IN THIS MANUAL
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING
THE CAR.
• 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.