Club Car 2008-2011 Maintenance And Service Manual page 222

8
IQ PLUS CHARGER (EXTERNAL)
5. 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 – Diodes on page 8-16. If diodes have not failed, check
the DC cord for a short circuit. See Test Procedure 8 – Continuity on page 8-20.
6. Remove the DC cord blue wire from the red wire connected to the charger relay and check continuity
between the positive and negative pins and middle pin on the DC plug (Figure 8-5, Page 8-9 and
Figure 8-6, Page 8-12). There should be no continuity.
Figure 8-12 DC Plug Test
TEST PROCEDURE 6 – TRANSFORMER
See General Warning, Section 1, Page 1-1. See additional WARNING on page 8-1.
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 8-15.
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Disconnect transformer secondary coil wires (1 and 5) from the heatsink (Figure 8-14, Page 8-19).
4. To apply AC power directly to the transformer primary coil, the relay must be bypassed.
4.1. To bypass the relay, remove the black wire (3) from the AC circuit breaker and disconnect the tan
wire (4) from the relay. Connect the tan wire (4) to the AC circuit breaker (Figure 8-14, Page 8-19).
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.
Page 8-18 2008-2011 Domestic Battery Charger Maintenance and Service Manual
POSITIVE PIN
PULL HERE PULL HERE
PULL HERE PULL HERE
NEGATIVE PIN
NEGATIVE PIN
Figure 8-13 DC Plug Test – Probes Reversed
Test Procedures
POSITIVE PIN
PULL HERE PULL HERE
PULL HERE PULL HERE