Club Car 2008-2011 Maintenance And Service Manual page 49

POWERDRIVE CHARGER (EXTERNAL)
Figure 3-18 Diode Test
Test Procedure 4B – Both Diodes Failed
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
To check the diodes, use Test Procedure 4A – Single Diode Failure on page 3-20. If both diodes have failed
closed, both charger fuse links will be blown. If both diodes have failed open, the relay will close and the trans-
former will hum, but the ammeter will not indicate any output and the AC circuit breaker may trip off. If both
diodes have failed open or closed, the entire heatsink must be replaced. To determine why both diodes failed:
1. Check the batteries and the receptacle to ensure that they are wired in the correct polarity (Figure 3-11,
Page 3-16 through Figure 3-16, Page 3-18). Also check the voltage and polarity at the receptacle.
2. Make sure the charger is wired correctly: The DC cord red wire should be connected to the center ter-
minal of the heatsink, the DC cord blue wire should be connected to the relay coil, and the DC cord black
wire should be connected to the left side of the ammeter (when viewed from inside the charger)
(Figure 3-9, Page 3-11). If a reverse polarity connection is made between the charger and the batteries,
both fuse links will blow when the DC cord is connected to the vehicle, whether or not the AC cord is
plugged into an outlet.
3. On rare occasions, both diodes may fail as a result of a lightning strike at the charging location.
4. Excessive heat due to a loose connection may also cause both fuse links to blow. Be sure fuse connec-
tions are tightened to 22 in-lb (2.5 N·m).
5. Ensure that the charger and vehicle are wired properly and all connections are clean and tight.
TEST PROCEDURE 5 – CHARGER DC CIRCUIT CONTINUITY TEST
See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Using a continuity tester (CC P/N 1011273) or multimeter set to 200 ohms, connect the test probes to the
pins marked (+) and (–) on the DC plug (Figure 3-20, Page 3-22). Note the reading.
3. Reverse the test probes and check the DC plug again (Figure 3-21, Page 3-22). The circuit should show
continuity in only one direction.
4. If the circuit does not show continuity in either direction and the charger fuse is not blown, individually
check all connections and the continuity of the DC cord and ammeter. See Test Procedure 8 – Conti-
nuity on page 3-24. Also check the diodes (heatsink). See Test Procedure 4 – Diodes on page 3-20.
DISCONNECTED
SECONDARY COIL
WIRE
2008-2011 Domestic Battery Charger Maintenance and Service Manual
Figure 3-19 Diode Test – Probes Reversed
3
Test Procedures
Page 3-21