Club Car 1998 DS, Maintenance And Service Manual Supplement

Page: 87 / 132

POWERDRIVE BATTERY CHARGER Test Procedures
1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-15
14
12, Page 14-15) .
4. Reverse the tester leads and check each diode again and note the reading (Figure 14-13, Page 14-15) . A diode is
designed to conduct current in one direction only; if a diode conducts current (shows continuity) in both direc-
tions, the complete heat sink assembly with diodes must be replaced. If a diode does not conduct current (does not
show continuity) in either direction, the entire heat sink 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 they are clean and tight. The
proper torque on the fuse link connections is 20 in.lb (2.2 N-m).
6. Be sure the charger is wired properly and all connections are clean and tight. See following WARNING .
Procedure 4B - Both Diodes Fail
To check the diodes, use diode test procedure 4A. If both diodes have failed closed, both charger fuse links will be
blown. If both diodes have failed open, the relay will close and the transformer will hum, but the ammeter will not
indicate any output. If both diodes have failed open or closed, the entire heat sink assembly must be replaced. To
determine why both diodes failed:
1. Check the batteries and the receptacle to be sure they are wired in the correct polarity. Also check the voltage
and polarity at the receptacle.
2. Make sure the charger DC plug is wired correctly; the red wire should be connected to the center terminal of
the heat sink assembly, the blue wire should be connected to the relay coil, and the black wire should be con-
nected to the left side of the ammeter (when viewed from inside the charger). If a reverse polarity connection
is made between the charger and the batteries, both fuse links will blow when the DC cord is plugged into the
vehicle, whether or not the AC cord is plugged into an outlet.
3. On rare occasions, both diodes may fail as the result of a lightning strike at the charging location.
4. Excessive heat due to a loose connection may also cause both fuse links to melt. Be sure fuse connections are
tightened to 20 in.lb (2.2 N-m).
5. Be sure the charger is wired properly and all connections are clean and tight.
• IF CONNECTIONS ARE NOT CLEAN AND TIGHT, EXCESSIVE HEAT COULD RESULT WHICH MAY DAMAGE THE
CHARGER.
Figure 14-12 Diode Test Figure 14-13 Diode Test–Reverse Probe Position
WARNING
DISCONNECT
SECONDARY
COIL LEAD