Club Car 2008-2011 Maintenance And Service Manual page 48

3
POWERDRIVE CHARGER (EXTERNAL)
6. If the circuit is not complete, check the wiring of the AC cord, transformer primary coil wires, and internal
AC circuit breaker (Figure 3-22, Page 3-23).
7. If the charger is wired correctly, check the continuity of the AC cord, transformer primary coil, and the
internal AC circuit breaker individually. See Test Procedure 8 – Continuity on page 3-24.
8. When troubleshooting and repairs are complete, properly connect the relay wiring. See following
WARNING.
ý
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.
TEST PROCEDURE 4 – DIODES
Use Test Procedure 4A – Single Diode Failure on page 3-20 for single diode failures and testing of individual
diodes. If both diodes have failed, use Test Procedure 4B – Both Diodes Failed on page 3-21.
Test Procedure 4A – Single Diode Failure
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
A single diode failure is indicated by the failure of one fuse link (closed circuit diode) or by the charger output
being low (open circuit diode). If a diode has failed, the entire heatsink must be replaced. To check diodes:
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Disconnect one transformer secondary coil wire from the diode terminal (Figure 3-18, Page 3-21).
4. Using a low voltage continuity tester or multimeter set to the diode test function, connect the red (+) test
probe to the diode mounting plate and the black (–) test probe to a diode terminal and note the reading
(Figure 3-18, Page 3-21).
5. Reverse test probes and check each diode again and note the reading (Figure 3-19, Page 3-21). A
diode is designed to conduct current in one direction only. If a diode conducts current (shows continuity)
in both directions, the entire heatsink with diodes must be replaced. If a diode does not conduct current
(does not show continuity) in either direction, the entire heatsink must be replaced.
6. On rare occasions, a single fuse link may blow due to excessive heat. This can be caused by a loose
internal fuse connection. Check all three fuse connections inside the charger to be sure they are clean
and tight. The proper tightness for the fuse link connections is 22 in-lb (2.5 N·m).
7. Ensure that the charger is wired properly and all connections are clean and tight. See following CAU-
TION.
CAUT ION
• If connections are not clean and tight, excessive heat will be created and the charger may
become damaged.
Page 3-20 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Test Procedures