Club Car 1998 DS, Maintenance And Service Manual Supplement

Page: 88 / 132

POWERDRIVE BATTERY CHARGER Test Procedures
Page 14-16 1998/1999 PowerDrive Plus Maintenance and Service Supplement
14
Test Procedure 5 - Charger DC Circuit Continuity Test
1. Using a continuity tester (Club Car Part No. 1011273) or multimeter set to 200 ohms, connect the test leads to
the pins marked (+) and (-) on the DC plug (Figure 14-14, Page 14-16) and note the readings.
2. Reverse the test leads and check the DC plug again (Figure 14-15, Page 14-16) . The circuit should show con-
tinuity in only one direction.
3. If the circuit does not show continuity in either direction and the charger fuse is not blown, individually check
the continuity of the DC plug and cord (Test Procedure 8) , ammeter (Test Procedure 8) , diodes (Test Proce-
dure 4A) , and all connections.
4. If the circuit shows continuity in both directions, a short circuit exists in the charger DC circuit, usually caused
by failed diodes. See Test Procedure 4 . If diodes have not failed, check the DC output cord for a short circuit
as described in Test Procedure 8 .
5. Remove the blue wire from the charger relay and check the continuity between the positive and negative
pins and the middle pin on the DC plug (Figures 14-4 and 14-5, Pages 14-7 and 14-8) . There should be no
continuity.
Test Procedure 6 - Transformer
Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns. If the transformer has failed, the
ammeter would indicate low output or no output; however, transformer may hum. A blown AC line fuse or circuit breaker
in the charger and/or storage facility may be caused by a failed transformer. To test the transformer:
1. Disconnect transformer secondary coil leads Nos. 1 and 5 from heat sink assembly (Figure 14-16, Page 14-
17) .
2. To apply AC power directly to the transformer primary coil, the relay must be bypassed.
3. To bypass the relay, 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 14-16, Page 14-17) .
4. Be sure secondary coil leads are not touching one another. With relay bypassed, insert AC plug into an outlet. If AC
line fuse or circuit breaker blows, the transformer is shorted internally and must be replaced.
5. If the AC line fuse or circuit breaker does not blow, check the transformer secondary voltage across lead Nos.1
and 5 using a multimeter set to 500 volts AC. If measured voltages are approximately 85 volts AC or lower for
the secondary coil, the transformer is shorted internally and must be replaced
(Figure 14-16, Page 14-17).
See following DANGER.
Figure 14-14 DC Plug Test Leads Figure 14-15 DC Plug Reverse Test Leads
POSITIVE PIN
NEGATIVE PIN
PULL HERE PULL HERE
PULL HERE
PULL HERE
POSITIVE PIN
NEGATIVE PIN
PULL HERE
PULL HERE
PULL HERE