Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 489 / 544

Page 23-17
E
23A
4. Place the probe of the tester on the negative (-) blade of the DC plug. The reading should be no conti-
nuity. If the reading is continuity, the cord and plug must be replaced.
5. Attach the alligator clip to the black wire of the DC cord and then place the probe on the negative (-)
blade of the DC plug. The reading should be continuity. If reading shows no continuity, the cord and
plug must be replaced.
Transformer:
The transformer has three coils that must be tested (Figure 23-16, Page 23-20).
1. Test the Primary Coil:
1.1. Disconnect the transformer primary coil leads from the terminals.
1.2. Place the continuity tester probes on the primary coil leads. The reading should be continuity. If
the reading is no continuity, replace the transformer.
2. Test the Secondary Coil:
2.1. Disconnect the transformer secondary coil lead from the upper terminal of the heat sink assem-
bly.
2.2. Disconnect the other transformer secondary coil lead from the upper terminal of the heat sink
assembly, then place the tester probes on the secondary coil leads (tan wires). The reading
should be continuity. If the reading is no continuity, replace the transformer. Be sure that the fuse
is intact and not blown.
3. Test the Capacitor Coil:
3.1. Disconnect the transformer capacitor coil leads from the capacitor terminals.
3.2. Place the tester probes on the capacitor coil leads. The reading should be continuity. If the read-
ing is no continuity, replace the transformer.
Relay:
1. Disconnect the two black wires from the contact terminals of the relay.
2. Place the continuity tester probes on the contact terminals of the relay. The reading should be no con-
tinuity. If the tester shows continuity, the relay contacts are welded shut and the relay must be replaced.
3. Plug the DC cord into a vehicle receptacle (make sure the vehicle batteries are connected), then place
the tester probes on the contact terminals of the relay. The reading should be continuity; if the tester
shows no continuity, the relay must be replaced.
Ammeter:
1. Disconnect both black wires from the left (when viewed from inside the charger) ammeter post.
2. Attach the alligator clip of the tester to one of the ammeter posts.
3. Place the tester probe on the other ammeter post. The reading should be continuity. If the tester shows
no continuity, the ammeter must be replaced.
• DO NOT ALLOW THE SECONDARY COIL LEADS TO TOUCH EACH OTHER. THERE ARE
APPROXIMATELY 61 VOLTS AC PRESENT.
• DO NOT ALLOW THE CAPACITOR COIL LEADS TO TOUCH EACH OTHER. THERE ARE
APPROXIMATELY 650 VOLTS AC PRESENT.
• HIGH VOLTAGE! WITH THE CHARGER ON, THE VOLTAGE OF THE CAPACITOR INSIDE THE
CHARGER IS APPROXIMATELY 650 VOLTS. USE EXTREME CAUTION WHEN WORKING
NEAR CAPACITOR TERMINALS.
• BEFORE PERFORMING THIS TEST, MAKE SURE THAT THE AC PLUG IS NOT PLUGGED IN.
DANGER
WARNING