Club Car 2008-2011 Maintenance And Service Manual page 53

POWERDRIVE CHARGER (EXTERNAL)
5. Disconnect the blue wire from the red wire assembly that connects to the charger relay.
6. Place the clip of the continuity tester on the red wire of the DC cord.
7. Place the continuity test probe on the positive (+) pin of the DC plug (positive (+) and negative (–) pins
are identified on the plug). If tester does not indicate continuity, the DC cord must be replaced.
8. Place the continuity test probe on the negative (–) pin of the DC plug. The tester should indicate no con-
tinuity. If tester registers continuity, the DC cord must be replaced.
9. Place the continuity test probe on the unmarked (middle) pin of the DC plug. The tester should indicate
no continuity. If tester registers continuity, the DC cord must be replaced.
10. Move the continuity tester clip to the black wire of the DC cord.
11. Place the continuity test probe on the negative (–) pin of the DC plug. The tester should indicate conti-
nuity. If tester does not indicate continuity, the DC cord must be replaced.
12. Place the continuity test probe on the unmarked (middle) pin of the DC plug. The tester should indicate
no continuity. If tester registers continuity, the DC cord must be replaced.
13. Move continuity test probe to the blue wire of the DC cord. Check for continuity at the middle pin. The
tester should indicate continuity. If tester does not indicate continuity, replace DC cord.
Transformer
The PowerDrive battery charger transformer has two sets of coils: a primary coil and a secondary coil
(Figure 3-22, Page 3-23).
Primary Coil
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Disconnect terminals from transformer (tan) primary coil transformer wires (4 and 6) (Figure 3-22,
Page 3-23).
4. Place the continuity tester probes on the disconnected primary coil transformer wires. The tester should
indicate continuity. If tester does not indicate continuity, replace the transformer.
Secondary Coil
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Remove the transformer (tan) secondary coil wire (1) from the upper terminal of the heatsink
(Figure 3-22, Page 3-23).
4. Remove the other transformer (tan) secondary coil wire (5) from the bottom terminal of the heatsink and
place the continuity test clip on the ammeter buss bar (7) (Figure 3-22, Page 3-23). Test for continuity
between the buss bar and each of the secondary coil wires (tan). The tester should indicate continuity
between the buss bar and both of the secondary coil wires. If tester does not indicate continuity on both
secondary coil wires, replace transformer. Ensure that the fuse is intact and not blown.
Voltage Suppressor – Failed Closed
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Using a multimeter set to the diode test function (
sense lead pin (short pin) of the DC plug. Place the red (+) probe on the positive (+) pin of the DC plug.
The multimeter should indicate no tone. If a tone is emitted (indicating a closed circuit) then the voltage
suppressor has failed and should be replaced. See following NOTE.
2008-2011 Domestic Battery Charger Maintenance and Service Manual
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), place the black (–) probe of the multimeter on the
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Test Procedures
Page 3-25