Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 512 / 544

Page 23-40
23B
E
Test Procedure 3, Continued:
7. If the circuit is not complete, check the wiring of the AC cord, transformer primary coil leads, internal
AC circuit breaker, and jumper wire (Figure 23-31, Page 23-43).
8. If the charger is wired correctly, check the continuity of the AC cord, transformer primary coil, and the
jumper wire individually (Test Procedure 8).
TEST PROCEDURE 4
Diodes:
Use test procedure 4A for single diode failures and testing of diodes. If both diodes have failed, use test pro-
cedure 4B.
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 23-27).
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 23-27).
4. Reverse the tester leads and check each diode again and note the reading (Figure 23-28). 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. See WARNING
below.
• 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 WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE
CHARGER.
• 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.
• IF CONNECTIONS ARE NOT CLEAN AND TIGHT, EXCESSIVE HEAT WILL BE CREATED AND
THE CHARGER COULD BE DAMAGED.
WARNING
WARNING