Club Car 2008-2011 Maintenance And Service Manual page 191

POWERDRIVE 3 – MODEL 26580
TEST PROCEDURE 6 – TRANSFORMER
See General Warning, Section 1, Page 1-1. See additional WARNING on page 7-1.
Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns. If the transformer
has failed, the ammeter will indicate low output or no output; however, the transformer may hum. A blown AC
line fuse or tripped AC circuit breaker in the charger or the storage facility may be caused by an improperly
wired charger or a failed transformer.
An AC circuit test should be done before performing this test procedure to ensure the continuity of the AC
cord, internal AC circuit breaker, and charger wiring. See Test Procedure 3 – AC Power and Continuity
Test of AC Circuit on page 7-19.
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Note wire locations for reassembly and then disconnect the orange and purple secondary coil trans-
former wires (1 and 2) from the diodes (Figure 7-9, Page 7-11).
4. To apply AC power directly to the transformer primary coil, bypass the relay. See step 4 of Charging a
Battery Pack that has Low Voltage on page 7-34. See following DANGER.
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DANGER
• Do not touch any wire or component in the battery charger while AC power is present. Failure
to heed this warning will result in an electric shock.
5. Make sure the secondary coil wires are not touching one another. With the relay bypassed, insert the AC
plug into an outlet. If the AC line fuse blows or AC circuit breaker trips, the transformer is shorted inter-
nally and must be replaced.
6. If the AC line fuse does not blow or the AC circuit breaker does not trip, check the transformer secondary
coil voltage.
7. Disconnect AC cord from the wall outlet.
8. Using alligator clips and a multimeter set to 500 volts AC, connect the multimeter probes to the second-
ary transformer coil wires (1 and 2).
9. Connect the AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage. If mea-
sured voltage is approximately 49.5 volts AC or lower for the secondary coil, the transformer is shorted
internally and must be replaced.
10. If the voltage reading is normal (50 volts AC or higher), the transformer is operational. Disconnect the AC
plug from the wall receptacle and check the continuity of the DC circuit. See Test Procedure 5 –
Charger DC Circuit Continuity Test on page 7-21.
11. When troubleshooting and repairs are complete, properly connect the relay wiring. See following
WARNING.
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WARNING
• The relay wiring must be properly connected prior to placing the charger back into normal
service. Failure to properly connect the relay wiring could result in property damage, severe
personal injury, or death.
2008-2011 Domestic Battery Charger Maintenance and Service Manual
7
Test Procedures
Page 7-23