Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 517 / 544

Page 23-45
E
23B
DC Cord and Plug
1. To check the continuity of the DC cord, disconnect the black wire of the DC cord from the ammeter.
2. Disconnect the red wire of the DC cord from the rectifier assembly.
3. Disconnect the blue wire from the relay.
4. Put the alligator clip of the continuity tester on the red wire of the DC cord.
5. Place the continuity tester probe on the positive (+) prong of the DC plug (the positive (+) prong and
negative (-) prong are identified on the plug). If you do not register continuity (bulb does not light), cord
and plug must be replaced.
6. Place the continuity tester probe on the negative (-) prong of the DC plug. You should register no conti-
nuity (bulb should not light). If you do register continuity, cord and plug must be replaced.
7. Place the continuity tester probe on the unmarked (middle) prong of the DC plug. You should register
no continuity (bulb should not light). If you do register continuity, cord and plug must be replaced.
8. Move the continuity tester alligator clip to the black wire of the DC cord.
9. Place the continuity tester probe on the negative (-) prong of the DC plug. You should register continuity
(bulb should light). If you do not register continuity, cord and plug must be replaced.
10. Place the continuity tester probe on the unmarked (middle) prong of the DC plug. You should register
no continuity (bulb should not light). If you do register continuity, cord and plug must be replaced.
11. Move the alligator clip to the blue wire of the DC cord. Check for continuity at the middle prong; it
should read continuity.
Transformer
The PowerDrive battery charger transformer has two coils; a primary coil and a secondary coil (Figure 23-
31, Page 23-43).
Primary Coil
1. Disconnect terminals from transformer tan primary leads (4) and (6).
2. Touch the continuity tester leads on the primary coil leads. You should register continuity (bulb should
light). If you do not register continuity, replace the transformer.
Secondary Coil
1. Remove the transformer secondary coil lead (tan) from the upper terminal (1) of the rectifier assembly.
See DANGER below.
2. Remove the other transformer secondary coil lead (tan) from the bottom terminal (5) of the rectifier
assembly and place the alligator clip on the ammeter bus bar (7). Touch the continuity leads to each
secondary coil lead (tan). You should register continuity (bulb should light). If you do not register conti-
nuity, replace transformer. Be sure that the fuse is intact and not blown.
Relay
1. Remove the black and tan wires from the contact terminals of the relay (Figure 23-31, Page 23-43).
Place continuity tester leads on contact terminals of the relay. Tester should show NO continuity (bulb
should not light). If it shows continuity, the relay contacts are welded shut and the relay must be
replaced.
• HIGH VOLTAGE! DO NOT ALLOW SECONDARY COIL LEADS TO TOUCH EACH OTHER.
THERE ARE APPROXIMATELY 120 VOLTS PRESENT.
• BEFORE PERFORMING THIS TEST, BE SURE THE AC PLUG IS NOT PLUGGED IN.
DANGER
WARNING