Club Car Gasoline Service Manual page 483

Test Procedure 4A - Single Diode Failure:
A single diode failure is indicated by the blowing of one fuse link (short circuited diode) or by low charger out-
put (open circuit diode). If a diode has failed, the entire heat sink assembly must be replaced. To check the
diodes:
1. Unplug the AC cord from its outlet and unplug the DC cord from vehicle receptacle.
2. Disconnect one transformer secondary coil lead from the diode terminal (Figure 23-2, Page 23-2).
3. Using a low voltage continuity tester, place one tester probe on the diode mounting plate and the other
probe on a diode terminal and note the reading (Figure 23-9).
4. Reverse the tester probes and check each diode again (Figure 23-10). A diode is designed to conduct
current in only one direction. If a diode shows continuity in both directions, the complete heat sink
assembly with diodes must be replaced. If a diode shows no continuity in either direction, the complete
heat sink assembly must be replaced.
5. Check all three fuse connections inside the charger to be sure that they are clean and tight. It is possi-
ble that a loose internal fuse connection could create enough heat to cause a single fuse link to melt.
The proper torque on all fuse link connections is 20 in.lbs. (2.3 N-m).
6. Be sure that the charger is wired properly and that all connections are clean and tight.
CAUTION
• IF CONNECTIONS ARE NOT CLEAN AND TIGHT, EXCESSIVE HEAT WILL BE CREATED AND
THE CHARGER MAY BE DAMAGED.
FIGURE 23-9
Test Procedure 4B - Both Diodes Failed:
Use Test Procedure 4A to test diodes. If both diodes have failed closed (shorted), 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 indicate no output. If both diodes have failed open or have shorted, the entire heat sink assembly must be
replaced. The following steps should be used to determine why both diodes failed:
1. Check the batteries and the receptacle to be sure that they are wired in the correct polarity. Use a multi-
meter to check the voltage and polarity at the receptacle.
DISCONNECT
SECONDARY
COIL LEAD
REVERSE POSITIONS
OF VOM LEADS
FIGURE 23-10
Page 23-11
23A
E