Test Procedures - Club Car Gasoline Service Manual

ACCU-POWER BATTERY CHARGER TROUBLESHOOTING GUIDE
SYMPTOM
6. Charger output is low.
7. Charger turns off too soon.
8. Charger does not turn off.
9. AC line fuse or circuit breaker blows.

TEST PROCEDURES

GENERAL
The charger uses DC battery voltage to close the charger relay that activates the charger AC circuit. When
the charger is operating properly, there is a 2 to 5 second delay after the DC cord is plugged into the vehicle
before the relay closes. This delay allows time for the DC plug to make a secure connection with the recepta-
cle before the AC circuit is activated and AC power is supplied to the primary coil of the transformer. When
the relay closes an audible "click" can be heard, and then as power is supplied, the transformer should hum
and the ammeter should indicate the charge rate.
WARNING
• 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
VEHICLE OR 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.
TEST PROCEDURE 1
Battery Voltage is Too Low or Bad DC Plug Connection:
1. Check the DC plug and the receptacle for damage, dirt, corrosion, etc., that might prevent a good elec-
trical connection.
2. Measure the voltage at the receptacle using a volt/ohm meter (Figure 23-6, Page 23-8).
3. Measure battery terminal voltage between the postive post on battery No. 1 and the negative post on
battery No. 6 (Figure 23-7, Page 23-8). The voltage reading should be the same as at the receptacle.
NOTE
• TO CLOSE THE CHARGER RELAY, BATTERY VOLTAGE MUST BE BETWEEN 24 AND 50
VOLTS.
POSSIBLE CAUSES
1) One diode failed.
2) Transformer coil short-circuit failure.
1) AC power supply was shut off.
2) Batteries may be fully charged.
1) Electronic Timer Kit has failed.
2) Electronic Timer Kit is improperly wired.
3) Bad battery.
1) Electronic Timer relay.
2) AC plug or cord is shorted.
3) Failed transformer.
REFER TO
Test Procedure 4-A
Test Procedure 7
Test Procedure 3
Test Procedure 8
Test Procedure 2
Test Procedure 2
Section 22, Batteries
Test Procedure 2 or 9
Test Procedure 9
Test Procedure 7
Page 23-7
23A
E