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2008-2011 Domestic Battery Charger Maintenance and Service

1. eese 6 19 3 AC cord continuity check 6 19 SAC POWER ciones cite cres ete reden 6 19 4 rectifler atten 6 20 5 DC circuit continuity test 6 21 6 transformer sse 6 22 7 battery state of charge ss 6 23 8 continuity AC circuit breaker internal 6 26 AC cord and plug eeeeenee 6 23 ammeter 3 2 ert ic eee 6 26 DG CcOrd iuter dettes ER dies 6 25 relay 332 iiec ertet rice eite 6 26 transformer wicca alanine 6 25 voltage suppressor eeeeeneeeee 6 26 transformer installation cecinere nte nds 6 29 removal nec edere tante eid 6 29 testllig ua nime RE 6 22 6 25 troubleshooting ereere 6 12 voltage suppressor testilignicisei Se notte ect idee Se eS on Mee 6 26 PowerDrive 3 charger Model 26580 AC circuit breaker charger see circuit breaker AC cord installation re 7 33 removal ieot teet cede desee co 7 33 testing ordre A 7 24 ammeter installation a iecit teintes 7 31 terrioval 1 trece ee 7 31 testirig i i erc er ttr RR HER 7 27 batteries battery condition after a charge cycle 7 12 charging batteries that have low voltage 7 34 state of charge test eccerre 7 24 battery charger identification eee 2 1 installatiori nee RIEEREERESR 7 8 Operation uicit rei tte t
2. 10 48 V 9 77 V 10 53 V 10 57 V 10 55 V 10 33 V On Charge Voltage Battery no 2 was immediately suspected as the problem After checking battery no 2 with a hydrometer it was discovered that the negative post cell was completely dead Battery no 2 should be replaced with a bat tery that has the same age and usage as the other batteries in the set Page 10 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD Test Procedures BATTERY TROUBLESHOOTING EXAMPLES 6 Volt Batteries The following information represents a few examples of troubleshooting battery problems Example 1 Vehicle no 68 was suspected of having a bad battery due to its performance As a result the battery charger test was performed After a full charge the battery charger ammeter read 8 0 amps Next the on charge volt age test was performed and the following results were recorded BATTERY NO 1 2 3 4 5 6 7 8 On Charge Voltage 7 40 V 7 60 V 7 10 V 7 40V 7 70V 7 80V 7 80V 7 80V Battery no 3 appears suspect Batteries no 1 and 4 are also suspect Next a hydrometer test flooded lead acid batteries only or discharge test should be conducted on all batteries Hydrometer test results flooded lead acid batteries only BATTERY NUMBER CELL NUMBER 1 2 3 4 5 6 7 8 Cell 1 Positive Post 1 200 1 265 1 300
3. 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 8 20 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 8 16 for single diode failures and testing of individual diodes If both diodes have failed use Test Procedure 4B Both Diodes Failed on page 8 17 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 1 See additional WARNING on page 8 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 4 Using a low voltage continuity tester or multimeter set to the diode test function connect the red test Disconnect one transformer secondary coil wire from the diode terminal Figure 8 10 Page 8 17 probe to the
4. Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 6 23 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Onboard Computer on page 6 19 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 6 23 Failed transformer Test Procedure 6 Transformer on page 6 22 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 6 19 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 6 19 Charger failure See Testing Charger Operation on page 6 11 16 hour time out See Battery Warning Light on page 6 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Battery warning light illuminates for ten seconds at four second intervals with DC charger cord unplugged 25 seconds at 10 second intervals for Precedent vehicles Batteries
5. Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Be sure the fuse link is clean and tight not applicable to Precedent vehicles Be sure all wire connections at the receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 6 7 Page 6 9 Do not pull on the DC cord Figure 6 8 Page 6 9 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle WARNING CONTINUED ON NEXT PAGE 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 9 E POWERDRIVE 3 MODEL 26560 Charger Installation and Operation A WARNING Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug a
6. 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the fuse Figure 5 18 Page 5 24 Disconnect the red wire of the DC cord from the ammeter Disconnect the blue wire from the blue wire assembly that connects to the charger relay Place the clip of the continuity tester on the red wire of the DC cord NO on R 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 indicates 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 indicates continuity the DC cord must be replaced 10 Move the continuity test probe 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 indicates 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 m
7. 6 T 8 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 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 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 4 Using a low voltage continuity tester or multimeter
8. Sede TERMINAL 10 BLACK f RECEPTACLE To Solenoid BLACK TO NEGATIVE TERMINAL Figure 7 3 Charge Circuit and Battery Configuration 6 x 8 Volt Turf 1 and Carryall 1 Vehicles Page 7 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 The Charge Circuit PRECEDENT VEHICLES 4 X 12 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 7 4 Page 7 5 or Figure 7 5 Page 7 6 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the charger recepta cle is connected to the positive post of battery no 1 The gray wire from the onboard computer is con nected to the charger receptacle If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check wire continuity and connections between the charger receptacle onboard computer and batteries FRONT S SS CHARGER OF VEHICLE ON un N AVHO 8L Mov18 0 L SINGLE POSITION CONNECTOR ONBOARD o N 10 BLACK COMPUTER j Figure 7 4 Charge Circuit an
9. Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 7 19 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 7 19 Transformer primary coil Test Procedure 6 Transformer on page 7 23 Relay Test Procedure 8 Continuity on page 7 24 Failed ammeter Replace ammeter Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 8 Continuity on page 7 24 Failed diodes Test Procedure 4 Diodes on page 7 20 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 7 19 Failed transformer Test Procedure 6 Transformer on page 7 23 Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 7 24 Charger fuse link blows or receptacle fuse link blows Failed diodes Test Procedure 4 Diodes on page 7 20 Loose internal fuse connection Tighten connection Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Troubleshooting Guide continued on next page 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 13 POWERDRIVE 3 MODEL 26580 Troubleshooting POWERDRIVE 3 BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Charge
10. CHARGER REPAIRS See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 6 9 Page 6 11 and Figure 6 10 Page 6 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove the DC cord black wire from the fuse by loosening the nut on the fuse Figure 6 23 Page 6 27 Remove the DC cord red wire from the ammeter Remove the DC cord blue wire from the relay board assembly ogg F wo DN Using pliers squeeze the strain relief bushing and remove the DC cord DC CORD BLUE WIRE TO RELAY DC CORD BLACK WIRE TO FUSE 4 f DC CORD RED WIRE u N pets AMMETER STRAIN RELIEF BUSHING Figure 6 23 DC Cord 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 27 a POWERDRIVE 3 MODEL 26560 Charger Repairs DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base 2 Attach the red wire of the new DC cord to the ammeter Figure 6 23 Page 6 27 3 4 Attach black wire of the new DC cord to fuse Install the nut onto post of the fuse and tighten to 23 in Ib Attach the blue wire of the new DC co
11. Cub Car 2008 2011 Domestic Battery Charger Maintenance and Service Manual Domestic PowerDrive IQ Plus and High Frequency Battery Chargers Manual Number 103373121 Edition Code 0408D1010C FOREWORD Club Car battery chargers are designed and built to provide unsurpassed performance efficiency among chargers in their class however proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation This manual provides detailed information for the maintenance and repair of domestic Club Car battery charg ers and should be thoroughly reviewed prior to servicing the charger The procedures provided herein must be properly implemented and the DANGER WARNING and CAUTION statements must be heeded This manual was written for the trained technician who already has knowledge and skills in electrical and mechanical repair If the technician does not have such knowledge and skills attempted service or repairs to the vehicle or charger may render the vehicle or charger unsafe For this reason Club Car advises that all repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained technician Itis the policy of Club Car LLC to assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical rep r
12. NOTE The positive terminal of the rectifier is marked on the edge of the rectifier case The positive ter minal can also be identified by its orientation and the notch in the rectifier case 5 Connect the two black transformer secondary coil wires to the AC terminals on the rectifier 6 Connect the black wire from the charger fuse to the negative rectifier terminal See following CAU TION CAUTION Improper wiring of the rectifier could result in damage to the rectifier and cause the AC circuit breaker to trip 7 Install the charger cover and check charger for proper operation TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Transformer Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the black primary coil wire 5 from the charger relay Figure 5 17 Page 5 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 25 ES POWERDRIVE 2 CHARGER EXTERNAL Charger Repairs 4 Carefully cut the heatshrink that insulates the AC cord white wire 4 where it connects to the tan primary coil wire 5 Disconnect the AC cord white wire 4 from the primary coil tan wire 6 Remove the wire tie that secures the two black transformer secondary coil wires to the white wire from the ammeter 7 Disconnect the two black secondary coil transformer wires 1 and 5 from the re
13. PowerDrive Battery Charger CC P N ber 17930 11 101802201 17930 18 101802202 17930 19 101802203 AC input AC voltage 105 128 VAC acceptable range Frequency 60 Hz Power consumption Max AC current amps 10 71 10 71 10 71 DC output DC voltage VDC start of charge cycle 48 48 48 DC current amps start of charge cycle 17 Ju Me DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle 3 5 3 5 3 5 Dimensions Weight 10 25 in 10 25 in 10 25 in Case overall length 26 cm 26 cm 26 cm 7 8 687 in 8 687 in 8 687 in Case overall width 22 1 cm 22 1 cm 22 1 cm 9 0 in 9 0 in 9 0 in Case overall height 22 9 cm 22 9 cm 22 9 cm 74 in 108 in 108 in AC cord length 188 cm 274 3 cm 274 3 cm 103 in 144 in 240 in DC cord length 261 6 cm 365 8 cm 609 6 cm 31 Ib 31 6 Ib 33 Ib Weight 14 1 kg 14 3 kg 15 0 kg Mounting configuration Mounting Set on shelf wall mount with keyhole or hang securely u from ceiling Page 2 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications POWERDRIVE 2 CHARGER PowerDrive 2 Battery Charger CC PIN ner 22110 11 101802204 22110 18 101802205 22110 19 1
14. Test Procedure 6 Transformer on page 9 15 Relay Test Procedure 8 Continuity on page 9 17 Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 4 Diodes on page 9 13 Both Diodes failed Test Procedure 4B Both Diodes Failed on page 9 14 Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Failed transformer Test Procedure 6 Transformer on page 9 15 Failed ammeter Replace ammeter Troubleshooting Guide continued on next page 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 7 EN IQ PLUS CHARGER ONBOARD Troubleshooting IQ PLUS ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 9 17 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 9 13 Loose internal fuse connection Tighten connection Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B Both Diodes Failed on page 9 14 Charger output is low One diode failed Test Procedure 4A Single Diod
15. charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages POWERDRIVE 3 BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected Connect the batteries See Connecting The Batteries on page 1 4 Battery voltage is too low Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 7 16 Poor connection between plug and receptacle Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 7 16 DC plug and cord Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 7 16 and Test Procedure 5 Charger DC Circuit Continuity Test on page 7 21 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 7 19 Gray sense lead fuse is blown not applicable to Precedent vehicles Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 7 16 Receptacle fuse link is blown not applicable to Precedent vehicles See Electrical Components section in the appropriate maintenance and service manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet voltage
16. 1 250 1 280 1 260 1 260 1 260 Cell 2 1 285 1 275 1 290 1 270 1 295 1 265 1 265 1 265 Cell 3 Negative Post 1 265 1 270 1 275 1 265 1 280 1 275 1 275 1 275 After the hydrometer test it appears that battery no 1 is the problem Next the discharge test was per formed Discharge test results BATTERY NO 1 2 3 4 5 6 7 8 Discharge Voltage 3 80 V 5 25V 5 65V 525V 5 50V 5 60 V 5 70V 5 30 V After a discharge test which lasted 45 minutes battery no 1 is clearly shown to be the problem Battery no 4 should be watched a little more closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on charge voltage was recorded as follows BATTERY NO 1 2 3 4 5 6 7 8 On Charge Voltage 7 40 V 7 100 V 7 45V 7 6V 7 65V 7 50V 7 55V 7 65V Battery no 2 was immediately suspected as the problem After checking battery no 2 with a hydrometer it was discovered that the negative post cell was completely dead Battery no 2 should
17. 3 Attach the blue wire of the new DC cord to the control board Figure 4 22 Page 4 24 4 Attach black wire of the new DC cord to ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the inside nut 2 tighten the outside nut 1 1 4 turn Figure 4 23 Page 4 24 See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Tie the wires together as they were before the wire ties were removed See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 7 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m HEATSINK Heatsink Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 See preceding WARNING Remove the charger cover Remove both secondary coil transformer wires tan from the heatsink Figure 4 4 Page 4 6 R ON Remove the two red wires from the heatsink e Remove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Place heatsink against cha
18. 4 Install the charger cover and check charger for proper operation 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 29 POWERDRIVE 3 MODEL 26580 Charger Repairs TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 Transformer Removal 1 e Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 4 Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan pri Disconnect the black primary coil wire 5 from the charger relay Figure 7 22 Page 7 25 mary coil wire Disconnect the AC cord white wire 4 from the primary coil tan wire If equipped remove wire tie s securing transformer wires 7 Note wire locations for reassembly and then disconnect the orange and purple secondary coil trans former wires 1 and 2 from each diode Figure 7 9 Page 7 11 Remove the four screws that secure the transformer to the mounting brackets and remove the trans former Transformer Installation 1 Install the transformer with primary coil to the rear of the charger case Secure the transformer to the mounting brackets with four screws 2 Connect the orange and purple secondary coil transformer wires 1 and 2 to the diodes at the original locations Figure 7 9 Page 7 11 3 Connect the black transformer primary coil wire 5 to the charger relay Fi
19. 5 4 With relay bypassed there should be continuity across the AC cord blades Figure 9 8 Page 9 13 Ifthe circuitis not complete check the wiring of the AC cord AC cord reel transformer primary coil wires and internal AC circuit breaker Figure 9 11 Page 9 16 If the charger is wired correctly check the continuity of the AC cord AC cord reel transformer primary coil and the internal AC circuit breaker individually See Test Procedure 8 Continuity on page 9 17 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 Page 9 12 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Test Procedures EN Figure 9 8 AC Circuit Continuity Test TEST PROCEDURE 4 DIODES Use Test Procedure 4A Single Diode Failure on page 9 13 for single diode failures and testing of individual diodes If both diodes have failed use Test Procedure 4B Both Diodes Failed on page 9 14 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 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 di
20. 6 50 V 7 07 V 7 07 V Battery no 4 is near end of useful life 7 20V 7 20 V 6 67 V 7 33 V 6 27 V 7 33 V Battery nos 3 and 5 are near end of useful life 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a charge for an entire work shift However discharge time is dependent on the elec trolyte temperature The table shown gives the discharge times at various temperatures of a set of bat teries that delivers 62 minutes at 80 F 26 7 C ELECTROLYTE DISCHARGE TIME TO ELECTROLYTE DISCHARGE TIME TO TEMPERATURE SHUT OFF POINT TEMPERATURE SHUT OFF POINT 40 49 F 85 89 F 4 9 C 40 Minutes 29 32 C 64 Minutes 50 59 F i 89 99 F 1 0 15 C 45 Minutes 32 37 C 66 Minutes 60 64 F 100 109 F 16 18 C 50 Minutes 38 43 C 68 Minutes 65 69 F F 110 119 F i 18 21 C 54 Minutes 43 48 C 70 Minutes 70 74 F 120 129 F 21 23 C 57 Minutes 49 54 C 72 Minutes 75 79 F 130 150 F 24 26 C 60 Minutes 54 66 C 74 Minutes 80 84 F F CN 27 29 C 62 Minutes 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 17 HIGH FREQUENCY CHARGER ONBOARD Interpreting Discharge Test Results 6 Volt Batteries 1 If discharge time is 60 minutes or higher the problem is not with the batteries Tes
21. Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on charge voltage was recorded as follows BATTERY NO 1 2 3 4 On Charge Voltage 15 72 V 14 66 V 15 80 V 15 85 V Battery no 2 was immediately suspected as the problem After checking battery no 2 with a hydrometer it was discovered that the negative post cell was completely dead Battery no 2 should be replaced with a bat tery that has the same age and usage as the other batteries in the set 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 19 HIGH FREQUENCY CHARGER ONBOARD BATTERY TROUBLESHOOTING EXAMPLES 8 Volt Batteries The following information represents a few examples of troubleshooting battery problems Test Procedures Example 1 Vehicle no 68 was suspected of having a bad battery due to its performance As a result the battery charger test was performed After a full charge the battery charger ammeter read 8 0 amps Next the on charge volt age test was performed and the following results were recorded BATTERY NO 1 2 3 4 5 6 On Charge Voltage 10 15 V 10 60 V 9
22. 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 8 17 11 When troubleshooting and repairs are complete properly connect relay wiring See following WARN ING A 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 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and then reconnect it The ammeter should jump to a reading between 14 and 18 amps and then taper to below 5 amps within 15 minutes 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Onboard Computer on page 8 15 See following NOTE 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 19 EN IQ PLUS CHARGER EXTERNAL Test Procedures NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Section 13 Batteries in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning
23. EXTERNAL External Charger Installation and Operation EN Figure 8 3 Charger Receptacle Figure 8 4 Incorrect Charger Cord Removal EXTERNAL CHARGER PLUG AND RECEPTACLE When inserting the DC plug into the vehicle receptacle align the raised guide on the plug with the guide slot in the receptacle and slowly push the plug straight in Figure 8 3 Page 8 7 To disconnect the plug from the vehicle firmly grasp the plug not the cord Figure 8 4 Page 8 7 and slowly pull plug straight out See fol lowing WARNING and CAUTION A WARNING Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 8 3 The battery charger DC plug must be pulled slowly from the receptacle Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death A CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage The charger cord plug and receptacle are wear items and sho
24. NEG RECTIFIER WHITE RED BLACK i BLACK Al E BLACK Iu C Brown FUSE a s d GROUND 100 Ohm RELAY BOARD ASSEMBLY WITH SUPPRESSOR Figure 6 26 PowerDrive 3 Charger Wiring Diagram Relay Bypassed 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 35 SECTION 7 POWERDRIVE 3 MODEL 26580 A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 The battery charger DC plug must be pulled slowly from the receptacle Figure 7 7 Page 7 9 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 7 8 Page 7 9 GENERAL INFORMATION This section includes information pertaining to service of the PowerDrive 3 battery charger model numbers 26580 11 26580 18 and 26580 19 Figure 7 1 Page 7 1 Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor Figure 7 1 PowerDrive 3 Battery Charger The PowerDrive 3 battery charger is automatic and has no external controls When the charger is connected there is a 2 to 15 second delay before charging begins NOTE At one hour and at two hours into the charge cycle the charger will shut off in or
25. SVPP325511 and SVPP325510 AC input AC voltage range 85 265 VAC acceptable AC voltage nominal 120 VAC 230 VAC Frequency 45 65 Hz AC Power Factor nominal gt 0 99 120 VAC gt 0 98 230 VAC Power consumption AC current amps Max 12 Amps Nominal 9 5 Amps rms 120 VAC 5 Amps rms 230 VAC DC output DC voltage VDC nominal 48V DC voltage VDC maximum 68V DC current maximum 18 Amps Interlock current maximum 1 Amp Dimensions Weight Case overall length 11 in 28 cm Case overall width 9 7 in 24 6 cm Case overall height 4 3 in 11 cm Weight lt 11 Ibs lt 5 kg Mounting configuration Mounting Onboard Secured to the vehicle 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 2 9 SECTION 3 POWERDRIVE CHARGER EXTERNAL A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 The battery charger DC plug must be pulled slowly from the receptacle Figure 3 7 Page 3 9 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 3 8 Page 3 9 GENERAL INFORMATION This section includes information pertaining to service of the PowerDrive battery charger model numbers 17930 11 17930 18 and 179
26. Test Procedures Figure 9 12 AC Cord and Retractable Cord Reel Continuity Test Short AC Cord without Retractable Cord Reel Check continuity of the short AC cord without the retractable cord reel 1 Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 3 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 9 13 Page 9 18 Figure 9 13 Heatshrink Removal 4 Disconnect the short AC cord from the retractable cord reel 5 Remove the charger cover 6 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 9 14 Page 9 19 Page 9 18 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Test Procedures EN Figure 9 14 Short AC Cord Test 7 Disconnect the black wire 1 of AC cord from charger AC circuit breaker 8 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the short AC cord must be replaced 9 Place the red probe on the end of the green wire 2 and with the black
27. When operated on a 120 volt 60 Hz electrical system the following IQ Plus battery chargers have been listed by Underwriters Laboratories and by the Canadian Underwriters thereby meeting the criteria of the Canadian Standards Association IQ Plus onboard battery charger models 25260 11 and 25260 50 THE CHARGE CIRCUIT For vehicles with onboard chargers the charge circuit consists of the following components onboard charger onboard computer batteries The 10 gauge black wire from the charger connects to the onboard computer black lead wire The 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the neg Page 9 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Onboard Charger Operation EN ative post of battery no 8 Figure 9 4 Page 9 10 The 10 gauge red wire of the charger is connected to the positive post of battery no 1 for Turf 2 252 Carryall 2 252 and XRT 900 vehicles or the large post of the solenoid battery side for Carryall 6 Villager and TransPorter vehicles The 18 gauge gray wire from the charger connects to the onboard computer Figure 9 2 Page 9 3 To check the charge circuit check the connections between the 18 gauge gray wire from the OBC DC cord red wire DC cord black wire and the wire connections between the batteries Sa SOLID STATE ONBOARD SPEED CONTROLLER COMPUTER li n No 4
28. XRT 900 Carryall 6 and Transporter 4 and 6 Tighten four screws 1 securing the cord reel housing 2 and its backing plate 3 to 16 in Ib 1 8 N m Place new heatshrink tubing over the short AC cord and connect the short AC cord to the retractable cord reel Slide the tubing over the connection and carefully apply heat to shrink it Page 9 28 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Charging a Battery Pack that has Low Voltage EN ZB mo a D PF TURF 2 AND 252 CARRYALL 2 AND 252 XRT 900 TRANSPORTER 4 VILLAGER 6 TRANSPORTER 6 VILLAGER 8 CARRYALL 6 Figure 9 20 Retractable Cord Reel Mounting Details CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 A WARNING e Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 9 3 Page 9 6 e Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING
29. charge circuit sip 8 3 circuit breaker installation 8 28 removal eei iiciin ee ee ede ded dares 8 28 TESTING E E EE et asia redes 8 22 cord charger see AC cord or DC cord DC cord installation 8 24 removal i anirai eain 8 23 testing eere A ae 8 17 8 21 diodes charger see heatsink electrical system charge circuit iari uii eicit eerie 8 3 fuse link installation re 8 27 termoval 4 ie AIeHREIDENGERSeeIDR iS 8 27 heatsink installation re 8 24 removal nee toe e e s 8 24 testing neret bee eene 8 16 onboard computer testllig x See ses teeta ecto ig el 8 15 relay installation 3 5 1 Ieri 8 28 removal e e pins 8 28 INDEX TESTING m 8 22 suppressor voltage see voltage suppressor test procedures 1 faulty receptacle connection 8 13 1 low battery voltage seesssss 8 13 2 onboard computer sees 8 15 3 AC cord continuity check 8 15 9 AC BOWEN tae de e Eid 8 15 4 diodes eee regne eue 8 16 5 DC circuit continuity test 8 17 6 transformer sseseeenee 8 18 7 battery state of charge sssss 8 19 8 continuity AC circuit breaker internal 8 22 AC cord and plug oieee 8 20 ammeter 2 enter iter n Ree A Tees 8 22 DG Cord iicet ee 8 21 relays tee
30. e BATTERY ANHO 8L MOV1E OL SINGLE POSITION CONNECTOR ONBOARD COMPUTER SOLID STATE SPEED CONTROLLER Figure 5 3 Charge Circuit and Battery Configuration Precedent Vehicles CHARGER INSTALLATION AND OPERATION See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion Page 5 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Charger Installation and Operation E A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle The battery charger DC plug must be pulled slowly from the receptacle Figure 5 4 Page 5 5 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 5 5 Pag
31. when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger DC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 25 seconds 10 seconds for Limo vehicles if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 25 seconds at 10 second intervals 10 seconds at 4 second intervals for Limo vehicles if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The bat
32. 1 1 See additional WARNING on page 7 1 Relay Board Assembly Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect all wires from the relay Figure 7 9 Page 7 11 Remove two screws attaching relay to the front of the charger case c BON Remove the relay Relay Board Assembly Installation Install in reverse order of removal and tighten screws firmly Connect wires as shown Figure 7 9 Page 7 11 CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 AC Circuit Breaker Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the two black wires attached to the circuit breaker Figure 7 9 Page 7 11 4 With a pair of pliers squeeze in the retaining tabs on the sides of the circuit breaker and push the circuit breaker through the mounting hole in the face of the charger to remove Page 7 32 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 AC Circuit Breaker Installation Install in reverse order of removal CHARGER AC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 AC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 4 Carefully cut the heatshrink 7 th
33. 12 Remove the two red wires from the heatsink Remove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Place heatsink against charger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts that secure the heatsink to the case Tighten the bolts to 18 in Ib 2 0 N m Figure 8 5 Page 8 9 and Figure 8 6 Page 8 12 Connect the red wire from the DC cord and the red wire from the charger relay to the center terminal post on the heatsink Tighten nut to 18 in Ib 2 0 N m Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Page 8 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL 4 5 Connect the other secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Install the charger cover and check charger for proper operation TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 Transformer Removal 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the tan primary coil wire from the charger relay Figure 8 5 Page 8 9 and Figure 8 6 Page 8 12 Disconnect the AC cord white wire from the primary coil tan wire 5 Remov
34. 15 seconds Page 9 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Checking Battery Condition with an Onboard Charger EN 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 Monitor the ammeter for about 30 seconds Under normal operating conditions when the charger is on and the batteries are discharged one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero See following CAUTION and NOTE A CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage NOTE Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use
35. 2 Wait 20 seconds then reconnect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero All vehicles except Precedent If the vehi cle has been driven even if only a few feet the onboard computer will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle continues If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 5 6 Page 5 8 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 9 ES PO
36. 3 5 4 6 1 6 2 6 2 6 3 6 3 6 4 6 5 6 6 Charger Installation and Operation sessar eenean penenie ao nennen eene 6 8 AG Power Connection om debet ee n getto b e id m E et e tnde 6 9 Gharging Batteries x iie oe ote et Ug e eL hel petu M due Het tae Mte De Lao Lt Pg De eed dg 6 9 Testing Charger Operation pue dene a bene tte ee n date enue re Ee ER e Ge ede 6 11 DGGCord and Plug InSpectlon 2 irr ipn rper Pte re pee etie Da gU ET Dna epit 6 11 Checking Battery Condition After a charge Cycle sse 6 12 Start Charge Cycles 2t eet d XEM ORE e E Ucet Ne UR nd ered ad T 6 12 FrOUDIGSNO OMG ec TE 6 12 Test ProCedules cattivi tea bte O ETE ERT 6 16 Index of Test Procedures i e I E pte cet E UR AS t US ix ER Dee lat seg 6 16 Charger Repairs iii ciseeta ceede tive aiid aeeai Ai N E AN Nell deed EAA beee danas devise deen 6 27 DC Cord ociosas a Had rE EEE EEEE EEAS AAE EA EA TNE EEEE A 6 27 RROGUUTION E 6 28 MUCIUS T SLUT 6 29 PANIIT GUS assis EE 6 30 USC LAK EC 6 31 Relay Board Assembly s notat p ada ae attitude tox EPOR UE 6 32 Charger AC Circuit Breaker eese E trennen tranh LET 6 32 Charger AG Cord see eee peter E E DOM Rr te ORI ee DOE s Di na A 6 32 Charging a Battery Pack that has Low Voltage sssssseeeem emen 6 34 SECTION 7 POWERDRIVE 3 MODEL 26580 General Information 2 1 2 e Ed eic co Ee et De e
37. 8Lit 4 BATTERY BANK TO SOLENOID o m E e S SINGLE POSITION CONNECTOR ONBOARD COMPUTER SOLID STATE SPEED CONTROLLER Figure 7 6 Charge Circuit and Style C Battery Configuration 6 x 8 Volt Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 7 POWERDRIVE 3 MODEL 26580 Charger Installation and Operation CHARGER INSTALLATION AND OPERATION See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle The battery charger DC plug must be pulled slowly from the receptacle Figure 7 7 Page 7 9 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batt
38. Both Diodes Failed on page 8 17 Troubleshooting Guide continued on next page Page 8 10 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Troubleshooting EN IQ PLUS BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Charger output is low One diode failed Test Procedure 4A Single Diode Failure on page 8 16 Transformer coil short circuit failure Test Procedure 6 Transformer on page 8 18 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 8 15 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 8 15 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 8 19 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Onboard Computer on page 8 15 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 8 20 Failed transformer Test Procedure 6 Transformer on page 8 18 Incorrect ch
39. Case overall width dat m 18 1 e a i Case overall height 4B MS Ose Ds eae n AC cord length 1829 6m 264 aa 264 s DC cord length 264 a 365 8 cm 6086 ias 10 86 ka 1 ka ATB ke 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 2 5 CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications POWERDRIVE ONBOARD CHARGER SPECIFICATIONS PowerDrive Battery Charger Onboard Model number 17935 10 17935 20 17935 30 17935 40 CC P N 101814301 101814303 101814304 102546901 AC input AC voltage 105 128 VAC acceptable range Frequency 60 Hz Power consumption Max AC current amps 10 71 10 71 10 71 10 71 DC output DC voltage VDC start of charge cycle 48 48 48 48 DC current amps start of charge cycle 17 17 17 17 DC voltage VDC end of charge cycle 60 60 60 60 DC current amps end of charge cycle 3 5 3 5 3 5 3 5 Dimensions Weight 10 25 in 10 25 in 10 25 in 10 25 in Case overall length 26 cm 26 cm 26 cm 26 cm 7 8 687 in 8 687 in 8 687 in 8 687 in Case overall width 22 1 cm 22 1 cm 22 1 cm 22 1 cm 9 437 in 9 437 in 9 437 in 9 437 in Case overall height 24 cm 24 cm 24 cm 24 cm 17 ft 5 2 m 17 ft 5 2 m 17 ft 5 2 m 17 ft 5 2 m AC cord length retractable retractable retractable retractable 80 5 in 129 5 in 162 5 in 9 5 in
40. Charger Operation Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock Do not use an extension cord Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not use a battery charger if the cord or plug is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes a
41. Charger Relay Removal 1 Ov dm oy Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 Remove the charger cover Disconnect all wires from the relay Figure 9 19 Page 9 27 Remove two nuts and lock washers securing relay to the charger base Remove the relay Page 9 26 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Charger Repairs EN BLUE WIRE TO BLACK WIRE TO PRIMARY COIL STRAIN RELIEF BUSHING v sae N WHITE WIRE FROM AC CORD ELS BLACK WIRE TO GREEN GROUND CIRCUIT BREAKER WIRE Figure 9 19 Charger Relay Charger Relay Installation Install in reverse order of removal Connect wires as shown Figure 9 19 Page 9 27 Tighten nuts securing relay to charger base to 18 in Ib 2 0 N m CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 AC Circuit Breaker Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 2 Remove the charger cover 3 Disconnect the two black wires attached to the AC circuit breaker Figure 9 19 Page 9 27 4 Remove the nut on the front face of the charger that secures the breaker and remove the breaker from the charger AC Circuit Breaker Installation 1 Install in reverse order of removal Tighten nut firmly CHA
42. DC cord to ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the inside nut 2 tighten the outside nut 1 1 4 turn Figure 9 17 Page 9 22 See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Tie the wires together as they were before the wire ties were removed See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 7 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m HEATSINK Heatsink Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See preceding WARNING Remove the charger cover Remove both secondary coil transformer wires tan from the heatsink Figure 9 3 Page 9 6 B rere Remove the two red wires from the heatsink e Remove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Place heatsink against charger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts
43. DC plug and the vehicle charger receptacle for damage dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspectthe receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 DS DS Villager 4 Turf 1 Carryall 1 800 810 and 850 Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figure 6 3 Page 6 4 3 2 Make sure the two nuts that secure the two 10 gauge black wires to the receptacle fuse assembly are tight Figure 6 11 Page 6 16 CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER 7 LA LD e v om LEAD Figure 6 11 Receptacle Wire Connections all vehicles except Precedent 3 3 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sense lead fuse to the onboard computer gray wire See following WARNING Page 6 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Test Procedures EN A WARNING Do not bypass the sense lead fuse 3 4 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistance should be less than 2 ohms 3 5 Precedent Verify that the 10 gauge red wire from the charger receptacle is connected to the pos itive post of battery no 1 Figure 6 4 Page 6
44. Maintenance Charge x oge Green Flashing Absorption phase complete In Finish phase Solid AC Power good AC On Amber TRE Low AC Voltage Check voltage and power cord aS Flashing length see above for guidelines fan Charger error Reset charger power and refer to Fault Red IDS Flashing Troubleshooting Instructions below Charger Information Light Single LED display mounted on dash of vehicle Indication following Power On Self Test in EED which each light will flash once in order from red to green and amber Solid Charging complete Charger in Maintenance Mode Green 3 PE Short lt 80 Charge Flashing Long gt 80 Charge Amber Flashing Reduced Power Mode Low AC Voltage or High internal 9 charger temperature eee Charger error Reset charger power and refer to Reg Flashing Troubleshooting Instructions below Page 10 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD Onboard Charger Operation AC POWER CONNECTION A CAUTION Charger enclosure may be hot during charging Use hand protection if handling the charger while charging NOTE Make sure that the AC cord provided with your charger has the proper AC plug for your location If it does not contact your Club Car representative to obtain the proper cord or plug Only use ONE charger on a single 15 amp
45. Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge All electric vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 Page 1 4 thru Figure 1 8 Page 1 5 Never push objects of any kind into the battery charger case through the ventilation slots Failure to heed this warning could result in an electrical short circuit that could result in a fire Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death If battery wire terminals are damaged or corroded they should be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation and could result in a fire property damage or personal injury WARNING CONTINUED ON NEXT PAGE Page 1 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual SAFETY A WARNING Q Plus vehicles Use only 4 gauge AWG wires with low resistance terminals to replace battery wires on IQ Plus models Only IQ Plus chargers should be used with IQ Plus vehicles Long term use of a PowerDrive battery charger with IQ Plus ve
46. Rotation of the post could result in a damaged ammeter 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 27 POWERDRIVE CHARGER ONBOARD Charger Repairs 6 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 34 7 Check charger for proper operation FUSE LINK See General Warning Section 1 Page 1 1 Fuse Link Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 2 Remove the charger cover 3 Remove both black secondary coil transformer wires and the buss bar 3 from the back of the fuse link assembly Figure 4 24 Page 4 27 4 Remove screws from the front of the charger and remove the fuse link assembly Fuse Link Installation 1 Place clear plastic cover over fuse assembly and install mounting screws from front of charger face The center branch of the fuse assembly should be in the upper left corner when viewed from the front of the charger 2 Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 4 24 Page 4 27 Tighten to 22 in Ib 2 5 N m 3 Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tight
47. Service Manual rectifier installation esee 5 25 removal xe sd Ente 5 24 TESTING C 5 16 relay installation 5 28 removal x ISTE e eee 5 28 testing EE 5 22 suppressor voltage see voltage suppressor test procedures 1 faulty receptacle connection 5 13 1 low battery voltage 5 13 2 onboard computer ssssssssss 5 15 3 AC cord continuity check 5 15 3 AC power sss 5 15 A rectifier siii cider rne 5 16 5 DC circuit continuity test 5 17 6 transformer seeennmeee 5 18 7 battery state of charge sss 5 20 8 continuity AC circuit breaker internal 5 23 AC cord and plug seeen 5 20 ammelter J ede 5 22 DG scot ede ee ac ees 5 21 relay 2i Genie inGed ahaa is 5 22 transformer eese ntn 5 21 voltage suppressor ccecce 5 22 transformer installation iieri 5 26 removal 2 hee tmd 5 25 testing o tete ecd teams 5 18 5 21 troubleshooting eene 5 9 voltage suppressor se 5 28 installation ineo eterne 5 28 remoVal ninini iaieiiea 5 28 testllig 1 5 EA ETT 5 22 PowerDrive 3 charger Model 26560 AC circuit breaker charger see circuit breaker AC cord installation sinea a 6 33 removal nde neni eerie 6
48. TERMINAL BLACK TO f ONBOARD TERMINAL CHARGER BATTERIES Figure 4 2 Charge Circuit DS Villager 4 SOLID STATE ONBOARD l xX SPEED CONTROLLER COMPUTER TERMINAL CHARGER 1 RECEPTACLE No 10 RED RED TO No 10 RED POSITIVE Three Pin TERMINAL Connector BLACK TO f ONBOARD Tena CHARGER BATTERIES Figure 4 3 Charge Circuit Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 3 POWERDRIVE CHARGER ONBOARD Charger Operation CHARGER OPERATION See General Warning Section 1 Page 1 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Do not bypass the sense lead fuse Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 Do not connect the charger to battery packs that are not compatible with the DC output voltage sp
49. Warning Light on page 9 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Batteries are getting close to full discharge capacity Recharge batteries as soon as possible Page 9 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Test Procedures EN TEST PROCEDURES See General Warning Section 1 Page 1 1 INDEX OF TEST PROCEDURES Battery Voltage Control Board AC Power and Continuity Check of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test ONOOAR WD Continuity TEST PROCEDURE 1 BATTERY VOLTAGE See General Warning Section 1 Page 1 1 1 Check the wire connections between the vehicle and battery charger Figure 9 2 Page 9 3 1 1 Verify that the 10 gauge red wire from the battery charger is connected to the positive post of battery no 1 for Turf 2 252 Carryall 2 252 and XRT 900 vehicles or the large post of the solenoid battery side for Carryall 6 Villager and TransPorter vehicles 1 2 Verify the connection of the 10 gauge black wire from the onboard computer to the 10 gauge black wire from the battery charger 1 3 Check the connection of the 18 gauge gray wire from the charger to the onboard computer gray wire 1 4 Turf 2 252 Carryall 2 252 and XRT 900 Only Check the fuse in the 18 gauge gray wire 2 With
50. a continuity tester CC P N 1011273 or multimeter set to 200 ohms connect the test probes to the DC cord black wire and red wire terminals in the three pin connector Figure 9 11 Page 9 16 Note the reading 5 Reverse the test probes and check the DC cord again The circuit should show continuity in only one direction 6 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 9 17 Also check the diodes heatsink See Test Procedure 4 Diodes on page 9 13 7 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 9 13 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 9 17 8 Check continuity between the DC cord red black and blue wires Figure 9 3 Page 9 6 There should be no continuity TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 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
51. a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 8 Figure 9 4 Page 9 10 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 9 29 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 9 9 IQ PLUS CHARGER ONBOARD Test Procedures Place multimeter red probe here CARRYALL 2 AND 252 VEHICLES XRT 900 VEHICLES CARRYALL 6 VEHICLES STYLE B Place multimeter black probe here Place multimeter red probe here VILLAGER 6 AND 8 VEHICLES A FRONT y Place multimeter D OF VEHICLE black probe here Place multimeter Place multimeter red probe here black probe here Figure 9 4 Battery Configurations Page 9 10 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Test Procedures EN TEST PROCEDURE 2 CONTROL BOARD See General Warning Section 1 Page 1 1 DC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and blue wires remain connected to the vehicle All wires remain connected to the control board Se
52. a multimeter set to the diode test function place the positive probe of the multimeter on the pin marked positive on the DC plug Figure 7 20 Page 7 22 Place the negative probe on the pin marked negative The multimeter should indicate an overload no continuity 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 21 POWERDRIVE 3 MODEL 26580 Test Procedures POSITIVE PIN DIODE SETTING Figure 7 20 DC Plug Test 3 Reverse the test probes and check the DC plug again Figure 7 21 Page 7 22 The multimeter should indicate approximately 922 mV 4 If multimeter readings are incorrect check the battery charger wiring Figure 7 9 Page 7 11 5 If the multimeter indicates an overload no continuity in both directions and the charger fuse is not blown individually check all connections and the continuity of the DC cord and ammeter See Test Pro cedure 8 Continuity on page 7 24 Also check the diodes on the heatsink See Test Procedure 4 Diodes on page 7 20 6 Ifthe multimeter indicates a voltage reading in both directions a short circuit exists in the charger DC cir cuit usually caused by failed diodes See Test Procedure 4 Diodes on page 7 20 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 7 24 POSITIVE PIN PULL RERE x NEGATIVE PIN Figure 7 21 DC Plug
53. ammeter Install the charger cover 7 Plug the charger into the vehicle and check ammeter for proper operation Figure 8 18 Ammeter Page 8 26 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Charger Repairs EN FUSE LINK See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 Fuse Link Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove both black secondary coil transformer wires and the buss bar from the back of the fuse link assembly Figure 8 18 Page 8 26 4 Remove screws from the front of the charger and remove the fuse link assembly Fuse Link Installation 1 Place clear plastic cover over fuse assembly and install mounting screws from front of charger face The center branch of the fuse assembly should be in the upper left corner when viewed from the front of the charger 2 Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 8 18 Page 8 26 Tighten to 22 in Ib 2 5 N m 3 Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tighten to 22 in Ib 2 5 N m 4 Install the charger cover VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 See addit
54. are getting close to full discharge capacity Recharge batteries golf round may be completed first Onboard computer malfunction Test Procedure 2 Onboard Computer on page 6 19 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Page 6 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Troubleshooting EN BLACK WIRE TO SECONDARY FUSE LINK COIL WIRES PRIMARY COIL PRIMARY COIL _ TAN AND BLACK DC CORD BLACK WIRE T RSE je ae BLACK WIRE TO DC CORD a TUS CIRCUIT BREAKER RED WIRE DC conp TO AMMETER BLUE WIRE GREEN WHITE WIRE TO TO RELAY GROUND WIRE PRIMARY COIL SECONDARY COIL Figure 6 10 PowerDrive 3 Battery Charger Components Model 26560 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page6 15 E POWERDRIVE 3 MODEL 26560 Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 INDEX OF TEST PROCEDURES Battery Voltage and DC Plug and Receptacle Onboard Computer AC Power and Continuity Test of AC Circuit Rectifier Charger DC Circuit Continuity Test Transformer Battery State of Charge Test ON OORA WD Continuity TEST PROCEDURE 1 BATTERY VOLTAGE AND DC PLUG AND RECEPTACLE See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 1 Check the
55. battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 3 12 Page 3 17 Figure 3 12 DS DS Villager 4 800 810 and 850 Battery Voltage Test 4 2 Turf 1 and Carryall 1 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 3 13 Page 3 17 Place multimeter red 4 probe here FRONT OF VEHICLE Place multimeter black probe here Figure 3 13 Turf 1 and Carryall 1 Battery Voltage Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 17 E POWERDRIVE CHARGER EXTERNAL Test Procedures 4 3 Style A and B 4 x 12 Volt Precedent only With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 3 14 Page 3 18 or Figure 3 15 Page 3 18 200 DCV SETTING Figure 3 14 Battery Voltage Test Style A Battery Figure 3 15 Battery Voltage Test Style B Battery Configuration Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 RED probe to battery no 1 1 RED probe to battery no 1 2 BLACK probe to battery no 4 2 BLACK probe to battery no 4 4 4 Style C 6 x 8 Volt Precedent only With a multimeter set to 200 volts DC measure the voltage o
56. be replaced Ammeter 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 Remove the charger cover Disconnect the black wire from the left ammeter post as viewed from inside the charger Place the continuity tester clip on one of the ammeter posts Ow Be o T9 Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 2 Remove the charger cover 3 Disconnect the wires from the AC circuit breaker 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 23 POWERDRIVE CHARGER ONBOARD Charger Repairs 4 Place the continuity test probe on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuity replace the AC circuit breaker CHARGER REPAIRS See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 4 Page 4 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and re
57. be replaced with a bat tery that has the same age and usage as the other batteries in the set 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 21 HIGH FREQUENCY CHARGER ONBOARD Charger Repairs CHARGER REPAIRS See General Warning Section 1 Page 1 1 NOTE The high frequency charger offers no replacement parts If necessary the charger must be replaced See Onboard Charger Removal and Installation Section 10 Page 10 22 ONBOARD CHARGER REMOVAL AND INSTALLATION See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 10 3 Page 10 4 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle Onboard Charger Removal 1 Disconnect the batteries and discharge the controller See Disconnecting The Batteries on page 1 3 2 Remove the wire ties securing the AC cord to the body 3 Disconnect the charger AC cord from the charger harness 4 Disconnect the charger harness 10 pin plug from charger 5 Remove four lock nuts 5 securing charger to charger mounting plate 6 Remove charger from vehicle Onboard Charger Installation Precedent Vehicles 1 Installation is reverse of removal 2 Tighten four lock nuts to 40 in Ib 5 4 N m 3 Connect the batteries See Connecting The Batteries on page 1 4 Page 10 2
58. both diodes may fail as a result of a lightning strike at the charging location 5 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 Ib 2 5 N m 6 Ensure that the charger and vehicle are wired properly and all connections are clean and tight 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 15 POWERDRIVE CHARGER ONBOARD Test Procedures TEST PROCEDURE 5 CHARGER DC CIRCUIT CONTINUITY TEST Test Procedure 5A DS Villager 4 See General Warning Section 1 Page 1 1 1 2 3 Disconnect the AC cord from the wall outlet Connect the batteries See Connecting The Batteries on page 1 4 Disconnect the DC cord blue wire 17 from the 3 way wire adapter 18 at the sense lead fuse 20 Figure 4 28 Page 4 34 4 Disconnect the DC cord red wire from the positive post of battery no 1 5 Disconnect the DC cord black wire 19 from the charger receptacle fuse link Figure 4 28 Page 4 34 6 Using a continuity tester CC P N 1011273 or multimeter set to 200 ohms connect the test probes to the 10 DC cord black wire and the DC cord red wire Figure 4 20 Page 4 21 Note the reading Reverse the test probes and check the DC cord again Figure 4 20 Page 4 21 The circuit should show continuity in only one direction If the circuit does not show continuity in either direction and the charger fuse is not blown indi
59. ce eR 8 22 transformer 2 eret telo eere bes 8 21 voltage suppressor nren 8 22 transformer installation 1 teret 8 25 FEMOVAl 3 cti Are PE Pe E Ert 8 25 testirigs iet be eie DERE 8 18 troubleshooting sessesssesss 8 9 voltage suppressor ssssee 8 27 installation rre 8 27 remioVal tuere Rp 8 27 TESTING c 8 22 IQ Plus charger onboard AC cord short iristallatlor zu ree 9 28 removal 2 5 3 28 5 a RUE 9 27 ammeter installation ee 9 25 removal issih seit AU IIR a ed 9 24 testing 1 eee de ee ene ir de iens 9 21 batteries battery condition after a charge cycle 9 5 charging batteries that have low voltage 9 29 state of charge test ecen 9 17 battery charger installation oett rete 9 31 removal ist ees 9 31 i r eee leve E 9 22 testirigi y aa ds setae Deo uai 9 6 battery condition after a charge cycle 9 5 battery warning light ssessseeesss 9 2 charge circuit 2 ersten dee noai 9 2 circuit breaker installation cte eat eterne eite 9 27 removal 1 eite cerneret eerie 9 27 testirigi ttem 9 21 control board testing i eere teen eerte rece ies 9 11 cord charger see AC cord or DC cord DC cord installation sseeeeesseseeseen 9 22 reimowVal stitit oet none sewed et deed en ean 9 22 testing 5 cie
60. charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 7 2 Page 7 3 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD az SOLID STATE COMPUTER SPEED CONTROLLER FUSE LINK iN 10 BLACK a T N v Jp Y p Y 46 BLACK M N CHARGER 10 BLACK AL RECEPTACLE y 18 GRAY jr P SS 10 BLACK 10 RED SENSE LEAD FUSE Figure 7 2 Charge Circuit and Battery Configuration 4 x 12 Volt DS 800 810 and 850 Vehicles 2008 2011
61. charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle The battery charger DC plug must be pulled slowly from the receptacle Figure 6 7 Page 6 9 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 6 8 Page 6 9 Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use Each charger should have i
62. condition The Version 3 0 and 4 0 onboard computers will quickly flash the battery warning light on the dash to indicate a problem with the voltage supressor Relay 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove black 3 and tan 4 wires from contact terminals of the relay Figure 3 22 Page 3 23 Place continuity test probes on contact terminals of the relay The tester should indicate no continuity If tester indicates continuity the relay contacts have failed closed and the relay must be replaced 4 Place continuity test probes on contact terminals of relay With batteries connected insert DC plug into receptacle The tester should indicate continuity If tester does not indicate continuity relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the black wire from the left ammeter post as viewed from inside the charger 4 Place the continuity tester clip on one of the ammeter posts 5 Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker mo qe Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the wires from the AC circuit breaker Place th
63. 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 black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 5 21 Page 5 31 See following DANGER A 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 Plug the DC cord into the charger receptacle first and then plug the AC cord into an electrical outlet 6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 7 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 8 Disconnect the transformer wire 4 from AC circuit breaker and connect it to the relay Connect the short black wire 3 from the relay to the AC circuit breaker Figure 5 21 Page 5 31 See following WARN ING A 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 per
64. ee ER IRE ERA dE RE ERE RR REM ean Test PIrOCedutes ctio tote e ecMILI d EIL pP ML eco eid oa ahh had CM Seah Ne oh FROCUPIGR cas E RTT A caves A e AAE EE AE na daedee Gatdeven da eases ETS I cuui n Aimmeter codd cra OO EE Em OE a rans FUSOSEIAK DELI Voltage Su ppressot 1 22 2 rtr en EIER nro EL ORAE S ACUAERRE M e ORE CR RENE EAR E net aed Charger Relay men umen wennhdnee mpm unum aes Charger AC Circuit Breaker cccccecccccceceseenccaeeseeneeehesseccecensntacaeensnsetecdeeneanecensnseneaeedeeneenseeneneanes Charger AG Cord sits onim tas mii n PR Eoatblut re OI E Dex rusa cnn ra hls Charging a Battery Pack that has Low Voltage sss nemen SECTION 6 POWERDRIVE 3 MODEL 26560 General Inforrmation 2 tot pee cene o lee PE e eie dendo Sead Ere Pe eie exe E ga PowerDrive 3 Battery Charger Features sssssssssssseeeee ener Battery Warning EIGlt o etii oer toot m bed tta pM The Charge Circuit mE DS 800 810 and 850 Vehicles 4 x 12 Volt nana aa a aaa aia Turf 1 and Carryall 1 Vehicles 6 x 8 Volt ssssssssseeeeeenneemeeennnnemrennnn Precedent Vehicles 4 x 12 Volt c cecccccccccesceceddeeeceeeddeceeeeeeeeueneeeedsseneaeeeedeneaseeeddanenedsedseeaneeeteeeaees Precedent Vehicles 6 x 8 Volt iaieineea a AEE RAAEN EPE caen tnn denne e nna 2008 2011 Domestic Battery Charger Maintenance and Service Manual 5 1 5 2 5 2 5
65. expose charger to oil dirt mud or direct heavy water spray when cleaning vehicle Keep all AC connections clean and dry e f the detachable input power supply cord set is damaged replace with a cord that meets the following criteria UL or CSA listed approved detachable cord 3 conductor 16AWG minimum and rated For NorthiAmerica SJT terminating in a grounding type IEC 60320 C14 plug rated 250V 13A minimum Safety approved detachable cord 3 conductor 1 5mm minimum rated appropriately for industrial use The cord set must be terminated on one end with a grounding type input connector appropriate for use in the country of destination and on the other end an output grounding type IEC 60320 C14 plug For all other countries Page 10 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD TROUBLESHOOTING See General Warning Section 1 Page 1 1 A DANGER Troubleshooting 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 10 3 Page 10 4 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal and Installation on
66. from the relay to the AC circuit breaker Figure 3 28 Page 3 34 See following WARN ING A 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 9 Install the charger cover and the retaining screws 10 Plug the DC cord into the charger receptacle and plug the AC cord into an electrical outlet 11 Allow the charger to continue charging the batteries until the charger shuts off automatically 12 When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 35 SECTION 4 POWERDRIVE CHARGER ONBOARD A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 GENERAL INFORMATION This section includes information pertaining to service of the onboard PowerDrive battery charger Model number 17935 10 is used on the DS Villager 4 Model number 17935 40 is used on Precedent golf cars Depending on the geographic region the charger provided w
67. have to be bypassed to activate the charger See following WARNING A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 8 5 Page 8 9 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 3 Remove the charger cover 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 20 Page 8 30 See following DANGER A 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 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 29 EN IQ PLUS CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage I DIODES WITH DC CORD HEATSINK AC CIRCUIT BREAKER SECONDARY COIL E AMMETER PRIMARY COIL TRANSFORMER AC CORD Figure 8 20 IQ Plus Charger Wiring Diagram Relay Bypassed
68. if AC power to the charger is interrupted The light will go out when AC power is restored UL AND CSA LISTING When operated on a 120 volt 60 Hz electrical system the following IQ Plus battery chargers have been listed by Underwriters Laboratories and by the Canadian Underwriters thereby meeting the criteria of the Canadian Standards Association IQ Plus external battery charger model 25730 11 Page 8 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL The Charge Circuit EN THE CHARGE CIRCUIT The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 8 The positive terminal of the charger receptacle is connected to the positive post of battery no 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between th
69. in the charger adapter harness One wire con nects to the onboard computer black lead wire The second wire connects to the charger receptacle black lead wire Page 4 10 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Test Procedures 1 3 Verify the connection of the 18 gauge gray wires in the charger adapter harness One wire con nects to the onboard computer The second wire connects to the charger receptacle gray lead wire 2 Style A and B 4 x 12 Volt Precedent only With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 4 6 Page 4 11 or Figure 4 7 Page 4 11 L gt VEHICLE 200 DCV SETTING Figure 4 6 Battery Voltage Test Precedent Style A Figure 4 7 Battery Voltage Test Precedent Style B Battery Configuration Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 RED probe to battery no 1 1 RED probe to battery no 1 2 BLACK probe to battery no 4 2 BLACK probe to battery no 4 3 Style C 6 x 8 Volt Precedent only With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 4 8 Page 4 11 D i 7 Figure 4 8 Battery Voltage Test Precedent Style
70. ine ties eds Charger AG Circuit Breaker t eate t etc E OPE cer bap ER EE Eb eeu bn p ena de Charger AG COE ttbi ecole n pt nte bebes abi o irte Lan ec Pata o E e dde Charging a Battery Pack that has Low Voltage ssssssee emen SECTION 8 IQ PLUS CHARGER EXTERNAL Gerieral Information iie ne UI ER ELLO Fr e RU VERNA E EHE esa ea IQ Plus External Charger Features sese eene nnerenen nnne nnn nnns Battery Warning Light 1 edu eee ett en RE Ue e es Rt UL and CSA Listifig o eo eit e mde The Charge Circuit 2 2 rettet eet Eu n eH HR Dee TH and External Charger Installation and Operation ssssen enne External Charger AC Power Connection ssssssssssseeeeeene nennen nennen nnns Charging Batteries s m eeoidevobe cube nda Oi ares i tates External Charger Plug and Receptacle sssssssseee enne rne nnns Checking Battery Condition with an External Charger sssssssee emn Start Charge Cycle tace eee ice e e Rede vv tt dede dox te dad te dd d d leds Testing Charger Operation essences endee denn i eiia sede dad este dde Troubleshooting 0 05 iei pie Inn dienMeaei en MC Kus Index of Test Procedures sssi enana a RANE eiTe a ATES AA PAAA RE ATE RTA a Charger RepallS 2 5 deett desi tae te A E AROTAR OORA DG COM D uli E mE Jcttin d a A SR E E AA R AES aa ATAS E E EE Nulla nl RE AA BEOTI E E PEA
71. on the disconnected secondary coil wires The tester should indicate continuity If tester does not indicate continuity replace the transformer Voltage Suppressor Failed Closed 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Using a multimeter set to the diode test function place the black probe of the multimeter on the 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 NOTE All vehicles except Precedent Repeated failure of sense lead fuses is a symptom of a voltage supressor that has failed in a closed condition Precedent vehicles only Failure of the onboard computer due to a blown internal sense lead fuse is a symptom of a voltage supressor that has failed in a closed condition Relay 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove black wires 3 and 4 from contact terminals of the relay Figure 5 6 Page 5 8 Place conti nuity test probes on contact terminals of the relay The tester should indicate no continuity If tester indi cates continuity the relay contacts have failed closed and the relay must be replaced Place cont
72. onboard computer by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehicle 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Using a multimeter set to the diode test function place the black probe of the multimeter on the 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 1 5 3 volts If a reading of 5 volt then the voltage suppressor has shorted and the relay should be replaced If the meter indicates an overload condition then the voltage suppressor has failed and the relay should be replaced See following NOTE NOTE All vehicles except Precedent Repeated failure of sense lead fuses is a symptom of a voltage supressor that has failed in a closed condition Precedent vehicles only Failure of the onboard computer prior to Version 3 0 due to a blown internal sense lead fuse is a symptom of a voltage supressor that has failed in a closed condition The Version 3 0 and 4 0 onboard computers will quickly flash the battery warning light on the dash to indicate a problem with the voltage supressor Relay 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove black wi
73. or extension cord Extension cord or outlet must accept grounded three blade plug The use of an improper extension cord could result in fire or electric shock Chargers can ignite flammable materials and vapors Do not use near fuels grain dust solvents thinner or other flammables Keep charger dry Do not expose to rain Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other materials to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes Page 3 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Charger Installation and Operation E Note Appearance of Note Appearance of receptacle receptacle may vary may vary depending on vehicle depending on vehicle Figure 3 7 Charger Receptacle Figure 3 8 Incorrect DC Plug Removal AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions With charger DC output cord disconnected connect the power suppl
74. pliers put the strain relief bushing on the cord and insert it into the charger base 6 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m RECTIFIER Rectifier Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 4 Remove the nut 1 lock washer 2 and screw 3 from the rectifier and remove the rectifier from the Remove all four wires from the rectifier Figure 5 6 Page 5 8 heatsink Figure 5 19 Page 5 25 Page 5 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Charger Repairs EN Figure 5 19 Rectifier Rectifier Installation 1 Thoroughly clean the heatsink plate in the area where the rectifier will be mounted 2 Apply a liberal amount of white thermal paste to the flat portion of the rectifier to ensure good thermal con ductivity from the rectifier to the heatsink plate 3 Place the rectifier against the heatsink plate so that the notch in the rectifier is oriented as shown Figure 5 19 Page 5 25 Install the screw 3 lock washer 2 and nut 1 through the hole in the charger case heatsink plate and rectifier Tighten the nut to 8 in Ib 0 9 N m 4 Connect the white wire from the ammeter to the positive terminal of the rectifier Figure 5 6 Page 5 8 See following NOTE
75. positive battery cable 3 Remove positive battery cable Connect battery cables in reverse order Connect battery cables in reverse order Figure 1 7 Transporter 4 and 6 IQ Plus and Carryall 6 Figure 1 8 Villager 6 and 8 IQ Plus Battery Style A IQ Plus Battery Configuration Configuration Viewed from driver side er vehicle Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables connecting battery cables 2 Remove negative battery cable 2 Remove negative battery cable 3 Remove positive battery cable 3 Remove positive battery cable Connect battery cables in reverse order Connect battery cables in reverse order 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 1 5 SECTION 2 CHARGER IDENTIFICATION AND SPECIFICATIONS BATTERY CHARGER IDENTIFICATION There are several different battery charger models available It is important to properly identify the battery charger type and model number before attempting to service a Club Car battery charger The battery charger can be identified by the model number printed on the charger Refer to the appropriate section of this manual as indicated in the chart below for information on troubleshooting repairing and or replacing the battery charger Do not attempt to service a battery charger that cannot be properly identified If a charger cannot b
76. properly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC wall outlet voltage should be between 105 and 128 volts If proper voltage is not present have building wiring checked by a licensed electrical contractor 5 Check continuity of the AC circuit 5 1 Remove the charger cover 5 2 Bypass the relay 5 2 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 5 3 With relay bypassed there should be continuity across the AC cord blades Figure 8 9 Page 8 15 Figure 8 9 AC Cord Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 15 EN IQ PLUS CHARGER EXTERNAL Test Procedures 6 T 8 If the circuit is not complete check the wiring of the AC cord transformer primary coil wires and internal AC circuit breaker Figure 8 14 Page 8 19
77. relay Figure 3 24 Page 3 27 8 Using pliers squeeze the strain relief bushing and remove the DC cord Figure 3 24 Page 3 27 DC CORD BLUE WIRE TO RED WIRE ASSEMBLY AT RELAY STRAIN RELIEF BUSHING Figure 3 24 DC Cord Figure 3 25 DC Cord Replacement 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 27 POWERDRIVE CHARGER EXTERNAL Charger Repairs DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base 2 Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18 in Ib 2 0 N m Figure 3 24 Page 3 27 3 Attach the blue wire of the new DC cord to the red wire assembly at the charger relay Figure 3 24 Page 3 27 4 Attach black wire 4 of the new DC cord to ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the inside nut 2 tighten the outside nut 1 1 4 turn Figure 3 25 Page 3 27 See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in ch
78. relay must be replaced Ammeter 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 Remove the charger cover Disconnect the black wire from the left ammeter post as viewed from inside the charger Place the continuity tester clip on one of the ammeter posts OV de or UND Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 2 Remove the charger cover 3 Disconnect the wires from the AC circuit breaker 4 Place the continuity test probe on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuity replace the AC circuit breaker 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 21 EN IQ PLUS CHARGER ONBOARD Charger Repairs CHARGER REPAIRS See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 9 3 Page 9 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 DC CORD DC Cord Remo
79. shut off in order to run a self diag nostic program ammeter will drop to zero See following NOTE NOTE If the batteries are in a fully charged state and the vehicle has not been driven the onboard com puter will not perform the self diagnostic test Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CC P N Page 6 10 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Charger Installation and Operation EN 101831801 See Communication Display Module in the appropriate maintenance and ser vice supplement If charger do
80. sufficient cooling air flow Reset charger interrupt AC power for 15 seconds yO Charger Internal Fault Reset charger interrupt AC power for 15 seconds Return to qualified service depot if fault persists 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 9 HIGH FREQUENCY CHARGER ONBOARD Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 INDEX OF TEST PROCEDURES 1 Battery Voltage Using Multimeter 2 Battery Condition Using Charger All Batteries 3 On Charge Battery Voltage Using Charger and Multimeter All Batteries 4 Hydrometer Test Flooded Lead Acid Batteries Only 5 Discharge Test All Batteries TEST PROCEDURE 1 BATTERY VOLTAGE USING MULTIMETER See General Warning Section 1 Page 1 1 1 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 for 4 x 12 volt battery set battery no 6 for 6 x 8 volt battery set or battery no 8 for 8 x 6 volt battery set 2 Normal no load voltage should be between 50 and 52 volts for a fully charged battery set Normal no load voltage of an individual battery should not be less than 0 5 volts of the other 7 batteries for 8 x 6 volt bat tery set or 0 7 volts of the other 5 batteries for 6 x 8 volt battery set or 1 0 volt of the other 3 batteries for 4 x 12 volt battery
81. suppressor has failed and the relay should be replaced See following NOTE NOTE All vehicles except Precedent Repeated failure of sense lead fuses is a symptom of a voltage supressor that has failed in a closed condition Precedent vehicles only Failure of the onboard computer prior to Version 3 0 due to a blown internal sense lead fuse is a symptom of a voltage supressor that has failed in a closed condition The Version 3 0 and 4 0 onboard computers will quickly flash the battery warning light on the dash to indicate a problem with the voltage supressor Page 7 26 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Test Procedures Relay 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove black wires 3 and 4 from contact terminals of the relay Figure 7 9 Page 7 11 Place conti nuity test probes on contact terminals of the relay The tester should indicate no continuity If tester indi cates continuity the relay contacts have failed closed and the relay must be replaced 4 Place continuity test probes on contact terminals of relay With batteries connected insert DC plug into receptacle The tester should indicate continuity If tester does not indicate continuity relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Discon
82. t p c E Poe dede ee a erp Sd 9 5 Testing Charger Operation 2 5 2 e is pv eR dct toe dude pede aant ue deua ee a e dead uad 9 6 Troubleshooting 1 erede ide dee exu e eee epo deer esta ed e sd denda idee 9 6 ESE PIOCSO USS ET MT 9 9 Index Of Test Procedures aede end eiae nete fo e eee REF e ce hanes tay wnagere Eu ae e uade 9 9 ierit 9 22 exeo M E M 9 22 miii deem 9 23 TAN STORMGN 3 ceed sats soe case beet EE 9 24 Amimeter ccena E E E enti Gans detathi im ata dune eet ate ae aes 9 24 FUS LINK T 9 26 Charger Relay iiie te itat deus 9 26 Charger AC Circuit Breaker sionen orrena AAEE AAEE A AEE TO rennen nnde o ERE FEREARE TEREA nne nna 9 27 Charger AC Cord and Retractable Cord Reel ssssssssssssseeeee nennen 9 27 Retractable AG Cord Reel 4 ceto n tee ore Pe Edi rere d te n 9 28 Charging a Battery Pack that has Low Voltage ssssseeeee emnes 9 29 Onboard Charger Removal and Installation sssssssee nennen nnne 9 31 SECTION 10 HIGH FREQUENCY CHARGER ONBOARD General Domator 1i took terc E odes cdech suuedcagesyh dadeanes sand deen oH LE Soci nen eH 10 1 I II 10 2 Uad GSA Listing 5 prater b EE teat tito Merit ee iyd eL letdgg 10 2 CE Gomlpllance 275 tere ter t pocta on T pe RI M itg 10 2 IP Ingress Protection Rating esssssseenneeeene nennen nennen nennen nnns 10 2 How To Identify Charge Algorithm Number ssssseseeeeeneemee
83. tede ten 4 13 4 diodes ee 4 14 5 DC circuit continuity test 4 16 6 transformer sss 4 17 7 battery state of charge sssss 4 18 Page i 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual INDEX 8 continuity AC circuit breaker internal 4 23 AC cord with retractable cord reel 4 19 AC cord without retractable cord reel 4 19 ammeter 0 0 ee ceececcececeeceesseseeeeeeeceeeeceeansseseess 4 23 DO GOI innen ehe 4 22 relay Rc E EUER 4 23 retractable cord reel uuueueussss 4 21 transformer sss 4 23 transformer installation 4 26 removal 5 eet pisse tee ero DEREN 4 26 testing 1 see ere erdt ron 4 17 troubleshooting see 4 7 W WARNING definitiori Of ooo Recette Eee a 1 1 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page i 7 Ciub Car NOTES Your Comments Are Appreciated Contact Information Optional Name am Title Company Distributor Dealer Address Individual Owner Club Car Associate Representative City State Zip Technician Phone Fax Golf Course Superintendent E mail Other Rate Our Publication In order to help us better s
84. that secure the heatsink to the case Tighten the bolts to 22 in Ib 2 5 N m Figure 9 3 Page 9 6 2 Connectthe red wire from the DC cord and the red wire from the control board to the center terminal post on the heatsink Tighten nut to 18 in Ib 2 0 N m 3 Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 4 Connect the other secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 9 31 6 Check charger for proper operation 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 23 EB IQ PLUS CHARGER ONBOARD Charger Repairs TRANSFORMER See General Warning Section 1 Page 1 1 Transformer Removal 1 NO a RON Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 Remove the charger cover Disconnect the black primary coil wire from the charger relay Figure 9 3 Page 9 6 Disconnect the tan primary coil wire from the control board Remove the wire tie that secures the DC cord wire to the secondary coil wire tan Disconnect the two tan secondary coil transformer wires from the heatsink Figure 9 3 Page 9 6 Disconnect the two black secondary coil transfor
85. the AC line fuse blows or AC circuit breaker trips the transformer is shorted inter nally and must be replaced If the AC line fuse does not blow or the AC circuit breaker does not trip check the transformer secondary coil voltage 8 Disconnect AC cord from the wall outlet 9 Using alligator clips and a multimeter set to 500 volts AC connect the multimeter probes to the second ary transformer coil wires 1 and 5 10 Connect the AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced Figure 9 11 Page 9 16 11 Ifthe voltage reading is normal 86 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 9 14 12 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 Page 9 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Test Procedures EN TEST PROCEDURE 7 BATTERY STATE OF CHARGE TES
86. the charge cycle is inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 8 2 3 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 8 2 Page 8 3 and that the internal charger wiring is correct Figure 8 5 Page 8 9 Page 8 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Troubleshooting EN 2 DIODES WITH DC CORD HEATSINK LEGIT 2 fs BLACK Ae AMMETER t AC CIRCUIT BREAKER SECONDARY COIL PRIMARY COIL TRANSFORMER Figure 8 5 IQ Plus Battery Charger Wiring Diagram External Charger TROUBLESHOOTING See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 8 5 Page 8 9 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Use the following Troubleshooting Guide for troubleshooting IQ Plus external battery chargers model num bers 25730 11 257
87. the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES A WARNING Do not bypass the sense lead fuse Be sure the fuse link is clean and tight Be sure all wire connections at the receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 8 3 WARNING CONTINUED ON NEXT PAGE 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 5 EN IQ PLUS CHARGER EXTERNAL External Charger Installation and Operation Do not pull on the DC cord Figure 8 4 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or person
88. 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 6 19 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the two black transformer secondary coil wires 1 and 2 from the rectifier Figure 6 9 Page 6 11 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 6 34 See following DANGER A 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 Page 6 22 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Test Procedures EN 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 Ifthe 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 Connectthe AC cord to the wall outlet an
89. the test probes and check the DC cord again The circuit should show continuity in only one direction 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 4 19 Also check the diodes heatsink See Test Procedure 4 Diodes on page 4 14 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 4 14 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 4 19 Check continuity between the DC cord red black and blue wires Figure 4 4 Page 4 6 There should be no continuity TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 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 AC cord reel internal AC circuit breaker and charger wiring See Test Procedure 3 AC
90. tie s that secures the DC cord to the vehicle 7 Lift charger and reel assembly from vehicle 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 33 POWERDRIVE CHARGER ONBOARD Onboard Charger Removal and Installation Figure 4 28 Charger DC Cord Black Wire and Blue Wire DS Villager 4 Onboard Charger Installation 1 Installation is reverse of removal 2 Tighten hardware securing the black DC cord wire to 23 in Ib 2 6 N m and the red DC cord wire to 144 in Ib 16 N m 3 Install four bolts 21 flat washers 22 lock washers 23 and nuts 24 securing charger to chassis and tighten to 108 in Ib 12 N m Figure 4 27 Page 4 33 4 Connect the batteries See Connecting The Batteries on page 1 4 PRECEDENT VEHICLES Onboard Charger Removal 1 Connect the batteries See Connecting The Batteries on page 1 4 2 Disconnect the charger DC cord at the three pin connector 1 Figure 4 29 Page 4 35 3 Remove four bolts 2 flat washers 3 lock washers 4 and nuts 5 securing charger to chassis 4 Lift charger assembly from vehicle Page 4 34 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Onboard Charger Removal and Installation Onboard Charger Installation 1 Installation is reverse of removal 2 Install four bolts 2 and nuts 5 securing charger to chassis and tighten to 108 in Ib 12 N m 3 Connect the batteries See Connecting The Bat
91. to run a self diagnostic program the ammeter will drop to 0 Charging will resume in a few moments ammeter will return to previous rate of charge 4 All vehicles Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 5 All vehicles except Precedent Monitor the ammeter for about 30 seconds Under normal operating conditions when the charger is on and the batteries are discharged the ammeter will drop to zero for 2 to 3 seconds at the beginning of each charge cycle in order to perform a self diagnostic test This test will be repeated at one hour and two hours into the charge cycle See following NOTE NOTE If the batteries are in a fully charged state and the vehicle has not been driven the onboard com puter will not perform the self diagnostic test Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold batteries
92. vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD SOLID STATE COMPUTER SPEED CONTROLLER lif FUSE LINK ii if m NE 10 BLACK Hn l Jue STETIT TERMINAL RED TO 6 BLACK MES B POSITIVE Sede TERMINAL 10 BLACK f RECEPTACLE To Solenoid BLACK TO NEGATIVE TERMINAL Figure 3 3 Charge Circuit and Battery Configuration Turf 1 and Carryall 1 Page 3 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL The Charge Circuit EU PRECEDENT 4 X 12 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 4 Page 3 5 or Figure 3 5 Page 3 6 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the charger recepta cle is connected to the positive post of battery no 1 The gray wire from the onboar
93. vehicle charging circuit is not functioning properly See Troubleshooting on page 3 12 5 Connectthe first charger into another vehicle that is known to be functioning properly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT 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 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC wall outlet voltage should be between 105 and 128 volts If proper voltage is not present have building wiring checked by a licensed electrical contractor 5 Check continuity of the AC circuit 5 1 Remove the charger cover 5 2 Bypass the relay 5 2 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 3 22 Page 3 23 5 3 With relay bypassed there should be continuity across the AC cord blades Figure 3 17 Page 3 19 Figure 3 17 AC Cord Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 19 POWERDRIVE CHARGER EXTERNAL Test Procedures
94. wall outlet 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC wall outlet voltage should be between 105 and 128 volts If proper voltage is not present have building wiring checked by a licensed electrical contractor 5 Check continuity of the AC circuit 5 1 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 5 2 Remove the charger cover 5 3 Bypass the relay 5 3 1 To bypass the relay remove the black wire 3 from the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 4 17 Page 4 18 5 4 With relay bypassed there should be continuity across the AC cord blades Figure 4 12 Page 4 14 6 Ifthe circuitis not complete check the wiring of the AC cord AC cord reel transformer primary coil wires and internal AC circuit breaker Figure 4 17 Page 4 18 7 If the charger is wired correctly check the continuity of the AC cord AC cord reel transformer primary coil and the internal AC circuit breaker individually See Test Procedure 8 Continuity on page 4 19 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 13 POWERDRIVE CHARGER ONBOARD Test Procedures 8 When troubleshooti
95. wire sense lead from the charger is connected through a 3 way wire adapter at the sense lead fuse to the gray wire that connects the charger receptacle to the onboard computer Page 4 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD The Charge Circuit Precedent Vehicles The 10 gauge black wire from the charger becomes two wires in the adapter harness Figure 4 3 Page 4 3 One wire connects to the onboard computer black lead wire The second wire connects to the charger recep tacle black lead wire The 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 Figure 4 6 Page 4 11 and Figure 4 7 Page 4 11 or battery no 6 Figure 4 8 Page 4 11 The 10 gauge red wire of the charger is connected to the positive post of battery no 1 The 18 gauge gray wire from the charger becomes two wires in the adapter harness One wire connects to the onboard computer The second wire connects to the charger receptacle gray lead wire To check the charge circuit check the connections between the 18 gauge gray wire from the OBC the sense lead fuse DC cord red wire DC cord black wire and the wire connections between the batteries a SOLID STATE ONBOARD IIT SPEED CONTROLLER COMPUTER I ih TTE ll TERMINAL IN CHARGER epee me I 10 BLACK iria o RED WIRES TO POSITIVE No 10 RED
96. wire tie s securing transformer wires 7 Disconnect the two black secondary coil transformer wires 1 and 2 from the rectifier Figure 6 9 Page 6 11 8 Remove the four screws that secure the transformer to the mounting brackets and remove the trans former Transformer Installation 1 Install the transformer with primary coil to the rear of the charger case Secure the transformer to the mounting brackets with four screws 2 Connect the two black secondary coil transformer wires 1 and 2 to the AC terminals of the rectifier Figure 6 9 Page 6 11 3 Connect the black transformer primary coil wire 5 to the charger relay Figure 6 22 Page 6 24 4 Place a piece of heatshrink tubing over the AC cord white wire 5 Connect the AC cord white wire 4 to the tan primary coil wire Figure 6 22 Page 6 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 29 E POWERDRIVE 3 MODEL 26560 Charger Repairs 6 Slide the heatshrink tubing 7 over the connection and apply heat to the heatshrink to insulate the con nection between the AC cord white wire and the tan primary coil wire See following WARNING A WARNING Make sure the electrical connections are properly insulated Failure to properly insulate electrical connections in the charger could result in a short circuit 7 lf equipped replace wire tie s securing transformer wires See following WARNING A WARNING Make sure wiring is pro
97. 0 DC OUTPUT DC voltage start of charge cycle 48 48 48 DC current start of charge cycle 14 5 14 5 14 5 DC voltage end of charge cycle 60 60 60 DC current amps end of charge cycle 4 5 4 5 4 5 DIMENSIONS WEIGHT 7 8 in 7 8 in 7 8 in Case overall depth 19 8 cm 19 8 cm 19 8 cm 7 13 in 7 13 in 7 13 in Case overall width 18 1 cm 18 1 cm 18 1 cm n 9 75 in 9 75 in 9 75 in Case overall height 24 8 cm 24 8 cm 24 8 cm 72 in 104 in 104 in AC cord length 182 9 cm 264 cm 264 cm 104 in 144 in 240 in DC cord length 264 cm 365 8 cm 609 6 cm 24 25 Ib 24 7 lb 25 35 Ib Weight 11 kg 11 2 kg 11 5 kg Page 2 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications POWERDRIVE 3 CHARGER PowerDrive 3 Battery Charger SPECIFICATIONS Mincir Model number 26580 11 26580 18 26580 19 Part number CCI 103499101 103499102 103499103 AC INPUT AC voltage 105 128 VAC Frequency 60 Hz POWER CONSUMPTION AC current amps 9 5 9 5 9 5 AC wattage watts 1140 1140 1140 DC OUTPUT DC voltage start of charge cycle 48 48 48 DC current start of charge cycle 14 5 14 5 14 5 DC voltage end of charge cycle 60 60 60 DC current amps end of charge cycle 4 5 4 5 4 5 DIMENSIONS WEIGHT Case overall depth 158 n 198 n iios n
98. 0 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the charger recepta cle is connected to the positive post of battery no 1 The gray wire from the onboard computer is con nected to the charger receptacle If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check wire continuity and connections between the charger receptacle onboard computer and batteries FRONT S SS CHARGER OF VEHICLE ON un N AVHO 8L Mov18 0 L SINGLE POSITION CONNECTOR ONBOARD o N 10 BLACK COMPUTER j Figure 6 4 Charge Circuit and Style A Battery Configuration 4 x 12 Volt Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 5 6 POWERDRIVE 3 MODEL 26560 The Charge Circuit CHARGER RECEPTACLE 0 J z COMPUTER Figure 6 5 Charge Circuit and Style B Battery Configuration 4 x 12 Volt Precedent Vehicles PRECEDENT VEHICLES 6 X 8 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 6 6 Page 6 7
99. 0 minutes throughout the rest of the test As soon as the battery set voltage reaches 0 5 volts above the shut off point 42 0 volts use a multim eter to measure individual battery voltages Measure and record the voltage of each battery to the near est 0 01 volt See following NOTE NOTE The tester will shut off automatically when shut off voltage is reached Figure 10 5 Battery Discharge Test Precedent Style Figure 10 6 Battery Discharge Test Precedent Style A Battery Configuration B Battery Configuration NC ie Uy iS A ISS KG Figure 10 7 Battery Discharge Test Precedent Style C Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 15 HIGH FREQUENCY CHARGER ONBOARD Interpreting Discharge Test Results 12 Volt Batteries 1 If discharge time is 60 minutes or higher the problem is not with the batteries Test Procedures 2 If discharge times are low less than 60 minutes replace batteries below 10 05 volts BATTERY VOLTAGES BATTERY CONDITION 2 3 4 10 50V 10 50V 10 50V 10 50V Excellent 10 60V 10 60V 10 83 V 9 75 V Battery no 4 is near end of useful life 10 8 V 10 8 V 10 01 V 9 41 V Battery nos 3 and 4 are near end of useful life 3 In general battery sets that discharge in less th
100. 01802206 AC input AC voltage 105 128 VAC acceptable range Frequency 60 Hz Power consumption Max AC current amps 9 0 9 0 9 0 DC output DC voltage VDC start of charge cycle 48 48 48 DC current amps start of charge cycle 13 13 13 DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle 3 5 3 5 3 5 Dimensions Weight 6 5in 6 5 in 6 5 in Case overall length 16 5 cm 16 5 cm 16 5 cm f 7 75 in 7 75 in 7 75 in Case overall width 19 7 cm 19 7 cm 19 7 cm 2 7 785 in 7 785 in 7 785 in Case overall height 19 8 cm 19 8 cm 19 8 cm 74 in 108 in 108 in AC cord length 188 cm 274 3 cm 274 3 cm 103 in 144 in 240 in DC cord length 261 6 cm 365 8 cm 609 6 cm 7 24 Ib 24 6 Ib 26 Ib Weight 10 9 kg 11 2 kg 11 8 kg Mounting configuration Mounting Set on shelf wall mount with keyhole or hang securely 2 J v from ceiling 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 2 3 CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications POWE RD RIVE 3 CHARGER PowerDrive 3 Battery Charger SPECIFICATIONS ROHBCASRUM Model number 26560 11 26560 18 26560 19 Part number CCI 103394401 103394402 103394403 AC INPUT AC voltage 105 128 VAC Frequency 60 Hz POWER CONSUMPTION AC current amps 9 5 9 5 9 5 AC wattage watts 1140 1140 114
101. 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD az SOLID STATE COMPUTER SPEED CONTROLLER FUSE LINK iN 10 BLACK a T N v Jp Y p Y 46 BLACK M N CHARGER 10 BLACK AL RECEPTACLE y 18 GRAY jr P SS 10 BLACK 10 RED SENSE LEAD FUSE Figure 6 2 Charge Circuit and Battery Configuration 4 x 12 Volt DS 800 810 and 850 Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 3 E POWERDRIVE 3 MODEL 26560 The Charge Circuit TURF 1 AND CARRYALL 1 VEHICLES 6 X 8 VOLT The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 6 3 Page 6 4 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the o
102. 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Onboard Computer on page 5 15 NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Section 13 Batteries in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Fuse 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord black wire from the fuse and position it so it does not touch any metal part of the charger Figure 5 18 Page 5 24 4 Using a multimeter set for 200 ohms place the red probe on one fuse terminal and the black probe on the other fuse terminal The tester should indicate continuity If the tester does not indicate continuity then the fuse has failed and must be replaced AC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 5 17 Page 5 20 Figure 5 17 AC Cord and Plug Continuity Test Page 5 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIV
103. 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual INDEX The following index is grouped in sections one sec tion for each type of battery charger in the manual Make sure that the battery charger has been prop erly identified before using the index See Battery Charger Identification Section 2 Page 2 1 B batteries hydrometer calibration 10 11 testing discharge test interpreting test results 12V 10 16 interpreting test results 6V 10 18 interpreting test results 8V 10 17 hydrometer test interpreting results 12V 10 12 interpreting results 6V 10 14 interpreting results 8V 10 13 C CAUTION definitionrof cei ite een nce 1 1 D DANGER definition OF eite n nien 1 1 High Frequency charger onboard 12 volt batteries troubleshooting examples 10 19 6 volt batteries troubleshooting examples 10 21 8 volt batteries troubleshooting examples 10 20 algorithm number ssssssse 10 3 battery charger installation etes 10 22 removal eevee vets eet er eet eere rene 10 22 IG Dal 8 ii ee deg 10 22 charge circuit sisca tocit aaa 10 4 charger displays sse 10 6 charge
104. 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Troubleshooting E POWERDRIVE 2 BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Troubleshooting Guide continued on next page Charger output is low Failed rectifier Test Procedure 4 Rectifier on page 5 16 Transformer coil short circuit failure Test Procedure 6 Transformer on page 5 18 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 15 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 15 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 15 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 5 20 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 15 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Section 13 Batteries in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 5 20 Failed transformer Test Procedure 6 Transformer on page 5 18 Incorrect charger wiring Check battery charger wiring Batt
105. 3 10 Page 3 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Use the following Troubleshooting Guide for troubleshooting PowerDrive external battery chargers model numbers 17930 11 17930 18 and 17930 19 The Troubleshooting Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages Page 3 12 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Troubleshooting POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected Connect the batteries See Connecting The Batteries on page 1 4 Battery voltage is too low Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 3 16 Poor connection between plug and receptacle Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 3 16 DC plug and cord Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 3 16 and Test Procedure 5 Charger DC Circuit Continuity Test on page 3 21 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 19 Gray sense lead fuse is blown not applicable to Precedent vehicles Test Pro
106. 30 18 and 25730 19 The Troubleshooting Guide encompasses the entire battery charg ing circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 9 E IQ PLUS CHARGER EXTERNAL Troubleshooting IQ PLUS BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected Connect the batteries See Connecting The Batteries on page 1 4 Battery voltage is too low Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 8 13 Poor connection between plug and receptacle Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 8 13 DC plug and cord Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 8 13 and Test Procedure 5 Charger DC Circuit Continuity Test on page 8 17 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 8 15 Gray sense lead fuse is blown Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 8 13 Receptacle fuse link is blown See Electrical Components section in the appropriate maintenance and service manual Poor connection of 10 gauge black wire or 18 gauge gray wire at the onboard computer Check wire connections Relay closes with a
107. 30 19 Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor The PowerDrive battery charger is automatic and has no external controls Figure 3 1 Page 3 1 When the charger is connected there is a 2 to 15 second delay before charging begins NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer having recorded the amount of energy consumed as the vehicle was used directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies Figure 3 1 PowerDrive Battery Charger 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 1 POWERDRIVE CHARGER EXTERNAL General Information POWERDRIVE EXTERNAL CHARGER FEATURES Charge Interlock PowerDrive battery charger DC plugs have three pins rather than two blades common on most stan dard charger plugs Two of these pins are the positive and negative leads as on standard chargers the third
108. 32 testing v e ede 6 24 ammeter installation e ete ipe 6 30 removal 5 ee edicere d 6 30 testlig E ect 6 26 batteries battery condition after a charge cycle 6 12 charging batteries that have low voltage 6 34 INDEX state of charge test ccenn 6 23 battery charger installation tete 6 8 Op6raltiOr 5 2 rere een 6 9 gcc 6 27 Specifications nianojn e poe 2 2 TESTING sition ih andl ena eth E 6 11 charge circuit 20 0 ee aai aiak 6 3 circuit breaker installation 1 eee Dee 6 32 removal 5 2 inerenti geret petens 6 32 testing 3 ee ee erede e estt etal 6 26 cord charger see AC cord or DC cord DC cord InSDeClHoLi wie niet Ud e i et be utes 6 11 installation sssseem 6 28 removal 5 25 ert Det 6 27 testing vec eevee nni cette fecere 6 21 6 25 diodes charger see rectifier electrical system ch rge cil CUil eroticos 6 3 fuse testirig rece eg 6 23 fuse link installation oe etes 6 31 removal eret RE ERE 6 31 long term storage charge 6 2 onboard computer testing roce ett ee EL ea bre A 6 19 rectifier installation ee 6 29 removal 1 ertt Ere dread en 6 28 relay installatiQni 2 etti 6 32 remioVal 22 eoe 6 32 TESTING onere er e aeree 6 26 test procedures 1 low battery voltage eessssss 6 16 2 onboard computer
109. 35 See following DANGER A 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 Plug the DC cord into the charger receptacle first and then plug the AC cord into an electrical outlet 6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 7 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 8 Disconnect the transformer wire 4 from AC circuit breaker and connect it to the relay Connect the black wire 3 from the relay to the AC circuit breaker Figure 7 25 Page 7 35 See following WARNING A 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 9 Install the charger cover and the retaining screws Page 7 34 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Charging a Battery Pack that has Low Voltage 10 Plug the DC cord into the charger receptacle
110. 5 4 Check battery pack voltage 4 1 DS DS Villager 4 800 810 and 850 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 6 12 Page 6 17 Figure 6 12 DS DS Villager 4 800 810 and 850 Battery Configuration 4 2 Turf 1 and Carryall 1 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 6 13 Page 6 17 Place multimeter red probe here FRONT OF VEHICLE Place multimeter black probe here Figure 6 13 Turf 1 and Carryall 1 Battery Configuration 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 17 E POWERDRIVE 3 MODEL 26560 Test Procedures 4 3 Style A and B 4 x 12 Volt Precedent only With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 6 14 Page 6 18 or Figure 6 15 Page 6 18 200 DCV SETTING Figure 6 14 Battery Voltage Test Precedent Style A Figure 6 15 Battery Voltage Test Precedent Style B Battery Configuration Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 RED probe to battery no 1 1 RED probe to battery no 1 2 BLACK
111. 5 Plug the DC cord into the charger receptacle first and then plug the AC cord into an electrical outlet 6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 7 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 8 Disconnect the transformer wire 4 from AC circuit breaker and connect it to the relay Connect the short black wire 3 from the relay to the AC circuit breaker Figure 8 20 Page 8 30 See following WARN ING A 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 9 Install the charger cover and the retaining screws 10 Plug the DC cord into the charger receptacle and plug the AC cord into an electrical outlet 11 Allow the charger to continue charging the batteries until the charger shuts off automatically 12 When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle
112. 6 Tighten the screw on the green ground wire terminal to 18 in Ib 2 0 N m 3 Position the strain relief bushing on the AC cord 4 Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 34 6 Check charger for proper operation RETRACTABLE AC CORD REEL See General Warning Section 1 Page 1 1 Retractable AC Cord Reel Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 2 Remove the charger cover 3 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 4 19 Page 4 20 4 Disconnect the short AC cord from the retractable cord reel Retractable AC Cord Reel Installation Install in reverse order of removal Page 4 30 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 4 Page 4 6 Prior to servicing the charger disconnect the
113. 80 V 10 16 V 10 56 V 10 61 V Battery no 3 appears suspect Batteries no 1 and 4 are also suspect Next a hydrometer test flooded lead acid batteries only or discharge test should be conducted on all batteries Hydrometer test results flooded lead acid batteries only BATTERY NUMBER CELL NUMBER 1 2 3 4 5 6 Cell 1 Positive Post 1 200 1 265 1 300 1 250 1 280 1 260 Cell 2 1 285 1 275 1 290 1 270 1 295 1 265 Cell 3 1 265 1 270 1 275 1 265 1 280 1 275 Cell 4 Negative Post 1 275 1 270 1 285 1 265 1 275 1 275 After the hydrometer test it appears that battery no 1 is the problem Next the discharge test was per formed Discharge test results BATTERY NO 1 2 3 4 5 6 5 44 V 7 33 V 7 73 V 7 15 V 7 43 V 7 41 V Discharge Voltage After a discharge test which lasted 45 minutes battery no 1 is clearly shown to be the problem Battery no 4 should be watched a little more closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on charge voltage was recorded as follows BATTERY NO 1 2 3 4 5 6
114. AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 If battery pack voltage is below 32 volts the charger will not activate The charger relay will have to be bypassed to activate the charger 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect the AC and DC cords and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 3 Remove the charger cover 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 black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 4 26 Page 4 32 See following DANGER A 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 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 34 6 Plug the AC cord into an electrical outlet The charger should activate and begin charging 7 Allow to charge for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed rela
115. ACK DC CORD RED WIRE GROUND WIRE TO AMMETER Figure 5 7 PowerDrive 2 Battery Charger TEST PROCEDURES See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 INDEX OF TEST PROCEDURES 1 Battery Voltage and DC Plug and Receptacle 2 Onboard Computer 3 AC Power and Continuity Test of AC Circuit 4 Rectifier 5 6 7 8 Charger DC Circuit Continuity Test Transformer Battery State of Charge Test Continuity Page 5 12 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Test Procedures Ea TEST PROCEDURE 1 BATTERY VOLTAGE AND DC PLUG AND RECEPTACLE See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Check the DC plug and the vehicle charger receptacle for damage dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspectthe receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle DS vehicles Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figure 5 2 Page 5 3 Precedent vehicles Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figure 5 3 Page 5 4 DS vehicles only 3 1 Make sure the two nuts that secure the two 10 gauge black wire
116. AMIM UGD cece 3 30 gra ER 3 31 Voltage Suppressor treeless ieee ees ne ele else eei dna cna ru dT ra ie ade ca deu dae LR ea codd 3 31 Charger Relay 2 1 pe dedii e de o E eit e d 3 32 Charger AC Circuit Breaker 24 isses i eite nnn ttn detnr dnd 3 32 Charger AC Cords aie Sui se ten itte A Eo et eA tete mati e oo Det ee 3 32 Charging a Battery Pack that has Low Voltage ssseee emen 3 34 SECTION 4 POWERDRIVE CHARGER ONBOARD General Information Lene etes e t debe Ee dde ede ase eee ve aede reed 4 1 PowerDrive Onboard Charger Features sssssssssssseeeeeeeneeneneeene nennen enne 4 2 Battery Warming Eight 21 2 1i id erede Ere dia LL Leda ee EREE ce d tuna gne due naa cue dada sonnel 4 2 THe Chard CIOU emm 4 2 Charger Operation 2 iie ettet en ete A ARATA E ARRS 4 4 Checking Battery Condition eee entente tnn nennen nenne sedent nennen nenas 4 6 TrOUbDISSNOOtING PR 4 7 iest PrOCedures ui tte roa T pec 4 9 Index of Test Procedures neranda a a aa E a e a a 4 9 Gharger ECLIPSE 4 24 DC GO d 2255 intei E a coh aa nas E Mom e iet a a e aN 4 24 alc E EE ENAA EIE TEE ETE E E A EE EATE NT 4 25 Tans ea doe ie ni T E TE 4 26 AMME eTa E 4 27 Fuse LINK arraien a a E utetdaw dnt eed a d ta ps 4 28 urls a M 4 28 Charger AC Circuit Breaker ciinii e nennen enne nenne sinere ne
117. BLACK No 10 RED Carryall 6 NS POSITIVE Transporter 4 and 6 TERMINAL Villager 6 and 8 Connector E SOLENOID No 10 RED XS P Three Pin Turf 2 and 252 Carryall 2 and 252 ONBOARD BLACK TO XRT 900 NEGATIVE BATTERIES CHARGER TERMINAL Figure 9 2 Charge Circuit ONBOARD CHARGER OPERATION A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger WARNING CONTINUED ON NEXT PAGE 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 3 EB IQ PLUS CHARGER ONBOARD Onboard
118. Be sure fuse connec 5 tions are tightened to 22 in Ib 2 5 N m 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 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 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 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 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 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 21 Test Procedures EJ E POWERDRIVE CHARGER EXTERNAL Test Procedures 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 3 20 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity o
119. 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 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
120. C Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 11 POWERDRIVE CHARGER ONBOARD Test Procedures 4 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 4 31 TEST PROCEDURE 2 CONTROL BOARD See General Warning Section 1 Page 1 1 DC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and blue wires remain connected to the vehicle All wires remain connected to the control board Set multimeter to 200 volts DC A DANGER Do not touch any wire or component in the battery charger while DC power is present Failure to heed this warning will result in an electric shock 2 Place black probe of multimeter on terminal with blue DC cord wire and red probe to terminal with red relay wire Figure 4 9 Page 4 12 BLUE WIRE RED WIRE TO DC TO RELAY NR BLACK WIRE 200 DCV SETTING 200 DCV SETTING IRE TO AC CIRCUIT TO TRANSFORMER BREAKER Figure 4 9 DC Circuit Test Figure 4 10 AC Circuit Test 3 Multimeter should indicate full
121. C plug to the receptacle The charger relay should close with an audible click after a 2 to 15 second delay See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 3 2 3 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 3 2 Page 3 3 through Figure 3 6 Page 3 7 and that the internal charger wiring is correct Figure 3 9 Page 3 11 DIODES WITH DC CORD HEATSINK AC CIRCUIT I BREAKER SECONDARY O 9 Ee BLACK FUSE AMMETER COIL PRIMARY COIL TRANSFORMER AC INPUT PLUG AC CORD Figure 3 9 PowerDrive Battery Charger Wiring Diagram External Charger DC CORD AND PLUG INSPECTION The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal an
122. CUIT CONTINUITY TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 8 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 CC P N 1011480 set to 200 ohms connect the test probes to the pins marked and on the DC plug Figure 8 12 Page 8 18 Note the read ing 3 Reverse the test probes and check the DC plug again Figure 8 13 Page 8 18 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 8 20 Also check the diodes heatsink See Test Procedure 4 Diodes on page 8 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 17 EN IQ PLUS CHARGER EXTERNAL Test Procedures 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 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 Fi
123. Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge between charges until the bat teries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries use the CDM Communication Display Module CC P N 101831801 See Communication Display Module in the appropriate main tenance and service supplement CHECKING BATTERY CONDITION WITH AN ONBOARD CHARGER Read DANGER WARNING and CAUTIONS beginning on page 9 3 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ Plus vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illu minate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual appropriate for your battery charger If you do not have this publication contact you
124. DC cord from the ammeter Disconnect the blue wire from the charger relay Place the clip of the continuity tester on the red wire of the DC cord N Oa s 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 indicates 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 indicates continuity the DC cord must be replaced 10 Move the continuity test probe 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 indicates 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 3 battery charger transformer has two sets of coils a primary
125. DC cord length 204 5 cm 328 9 cm 412 8 cm 24 cm Weight 37 Ib 16 8 kg 37 7 Ib 17 1 kg 38 2 Ib 17 3 kg 37 Ib 16 8 kg Mounting Configuration Mounting Onboard secured to the vehicle Page 2 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications SE CIEICA TIONS T CHARGER IQ Plus External Battery Charger Model number 25730 11 25730 18 25730 19 CC P N 102847801 102847802 102847803 AC input AC voltage 105 128 VAC acceptable range Frequency 60 Hz Power consumption Max AC current amps 13 0 13 0 13 0 DC output DC voltage VDC start of charge cycle 48 48 48 DC current amps start of charge cycle 17 17 17 DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle 4T ae 44 Dimensions Weight 10 25 in 10 25 in 10 25 in Case overall length 26 cm 26 cm 26 cm f 8 687 in 8 687 in 8 687 in Case overall width 22 1 cm 22 1 cm 22 1 cm 9 0 in 9 0 in 9 0 in Case overall height 22 9 cm 22 9 cm 22 9 cm 74 in 108 in 108 in AC cord length 188 cm 274 3 cm 274 3 cm 103 in 144 in 240 in DC cord length 261 6 cm 365 8 cm 609 6 cm a 31 0 Ib 31 0 Ib 31 0 Ib Weight 14 1 kg 14 1 kg 14 1 kg Mounting configuration Mounti
126. DIODES Use Test Procedure 4A Single Diode Failure on page 7 20 for single diode failures and testing of individual diodes If both diodes have failed use Test Procedure 4B Both Diodes Failed on page 7 21 NOTE This Powerdrive 3 Model 26580 uses two diode heatsink assemblies A running change installed these two diode heatsink assemblies in place of a rectifier mounted to an aluminum heat sink plate The model number with the rectifier was 26560 See Section 6 PowerDrive 3 Model 26560 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 1 See additional WARNING on page 7 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 diode 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 orange or purple from a diode terminal Figure 7 18 Page 7 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 7 18 Page 7 21 5 Reverse test probes and check each diode again and note the reading Figure 7 19 Page 7 21 A diode is designed to conduct curre
127. DITION AFTER A CHARGE CYCLE See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ System PowerDrive and Excel System vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual appropriate for your battery charger If you do not have this publication contact your Club Car representative If the specified test procedures identify no problems plug the DC cord into the vehicle and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle charger receptacle 2 Wait 20 seconds then reconnect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the veh
128. DRIVE CHARGER ONBOARD Test Procedures 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Control Board on page 4 12 See following NOTE NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Section 13 Batteries in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 Short AC Cord and Retractable Cord Reel Check continuity of the short AC cord and retractable cord reel at the same time 1 Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 3 Remove the charger cover 4 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 4 18 Page 4 20 e Disconnect the black wire 1 of the short AC cord from charger AC circuit breaker 6 Disconnect the AC cord white wire 4 from the control board Figure 4 17 Page 4 18 7 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Figure 4 18 Page 4 20 With the black probe test for continuity on each of the flat blades and then on the round pin of the AC plug on the retractable cord reel The tester should indicate co
129. Disconnect AC cord from the wall outlet 9 Using alligator clips and a multimeter set to 500 volts AC connect the multimeter probes to the second 10 ary transformer coil wires 1 and 5 Connect the AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced Figure 4 17 Page 4 18 11 Ifthe voltage reading is normal 86 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 4 16 12 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 1 With the batteries fully charged disconnect the AC charger plug for approximately 20 seconds and then reconnect it The ammeter should jump to a reading between 14 and 18 amps and then taper to below 5 amps within 15 minutes Page 4 18 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWER
130. Domestic Battery Charger Maintenance and Service Manual Page 7 3 POWERDRIVE 3 MODEL 26580 The Charge Circuit TURF 1 AND CARRYALL 1 VEHICLES 6 X 8 VOLT The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 7 3 Page 7 4 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD SOLID STATE COMPUTER SPEED CONTROLLER lif FUSE LINK ii if m NE 10 BLACK Hn l Jue STETIT TERMINAL RED TO 6 BLACK MES B POSITIVE
131. E 2 CHARGER EXTERNAL Test Procedures E 4 Disconnect the black wire 1 of AC cord from charger AC circuit breaker 3 5 Carefully cut the heatshrink that insulates the AC cord white wire 4 where it connects to the tan primary coil wire 6 Disconnect the AC cord white wire 4 from the primary coil tan wire 7 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced 8 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug Figure 5 17 Page 5 20 The tester should indicate continuity on only the round pin If any other reading is obtained the AC cord and plug must be replaced 9 Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only one flat blade If any other read ing is obtained the AC cord and plug must be replaced 10 Ifthe correct readings were obtained install the AC cord See AC Cord Installation on page 5 29 DC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover
132. Failed rectifier Test Procedure 4 Rectifier on page 6 20 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 6 19 Failed transformer Test Procedure 6 Transformer on page 6 22 Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 6 23 Charger fuse link blows or receptacle fuse link blows Failed rectifier Test Procedure 4 Rectifier on page 6 20 Loose internal fuse connection Tighten connection Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Troubleshooting Guide continued on next page 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 13 E POWERDRIVE 3 MODEL 26560 Troubleshooting POWERDRIVE 3 BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Charger output is low Failed rectifier Test Procedure 4 Rectifier on page 6 20 Transformer coil short circuit failure Test Procedure 6 Transformer on page 6 22 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 6 19 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 6 19 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 6 19
133. Figure 3 22 Page 3 23 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 3 22 Page 3 23 See following DANGER A 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 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 3 22 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Test Procedures EU 2 DIODES WITH DC CORD HEATSINK Lm e AC CIRCUIT BREAKER SECONDARY COIL AMMETER PRIMARY COIL TRANSFORMER Bc Figure 3 22 Transformer Test Wiring Diagram 6 Ifthe 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 5 9 Connectthe AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 85 volts AC or l
134. Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages POWERDRIVE ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer s Connect the batteries See Connecting Batteries disconnected hum and ammeter does not move The Batteries on page 1 4 Test Procedure 1 Battery Voltage on Battery voltage is too low page 4 10 See Figure 4 2 Page 4 3 Figure 4 3 Page 4 3 Figure 4 4 Page 4 6 Improper vehicle or battery charger wiring Figure 4 5 Page 4 10 Figure 4 6 Page 4 11 Figure 4 7 Page 4 11 and Figure 4 8 Page 4 11 Test Procedure 5 Charger DC Circuit DC circuit Continuity Test on page 4 16 Test Procedure 2 Control Board on Onboard computer malfunction page 4 12 Test Procedure 1 Battery Voltage on Gray sense lead fuse is blown page 4 10 Test Procedure 2 Control Board on Control board malfunction page 4 12 Troubleshooting Guide continued on next page 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 7 POWERDRIVE CHARGER ONBOARD Troubleshooting POWERDRIVE ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay closes with an audible click but no transformer hum and ammeter does not move Imp
135. NOTE NOTE The charger relay blade connector is located off center within the relay housing When connecting voltage suppressor slip on connector to relay blade connector make sure slip on connector is positioned so that flat side of connector is closest to relay housing CHARGER RELAY See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Charger Relay Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect all wires from the relay Figure 5 6 Page 5 8 4 Remove two screws nuts and lock washers attaching relay to the charger case 5 Remove the relay Charger Relay Installation 1 Install in reverse order of removal Connect wires as shown Figure 5 6 Page 5 8 Tighten nut securing relay to charger base to 18 in Ib 2 0 N m CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 AC Circuit Breaker Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the two black wires attached to the AC circuit breaker Figure 5 6 Page 5 8 Page 5 28 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage Eu 4 With a pair of pliers squeeze in the retaining tabs on the sides of the AC circuit breaker and remove the circui
136. PPROXIMATE TEMPERATURE STATE OF CHARGE CORRECTED 1 250 1 280 100 1 220 1 240 75 1 190 1 210 50 1 160 1 180 25 If the difference between the cells is 0 020 or more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery with the low cell should be replaced VEHICLE BATTERY ELECTROLYTE CORRECTION CORRESIED Scalia REQUIRED NE No TEMPERATURE goi CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 ACTION 1 275 1280 1280 1275 1280 1 280 12 1 Tn m 0 024 0 024 0 024 0 024 0 024 0 024 0 024 Pound Battery Fully l 1 251 1256 1256 1251 1256 1256 g ee 1 260 1200 1270 1265 1270 1 260 54 3 piel 0 012 0 0122 0 0422 0 0122 0 0122 0 0122 0 0122 Bad no 2 Cell 1 248 1 188 1258 1253 1258 1248 asa ee 1 200 1 180 1 170 1 200 1 180 1 198 piro ie 38 2 NEN 008 0 008 0 008 0 008 0 008 0 008 0008 Paley 1 208 1 188 1 178 1 208 1 188 1 198 g Recheck mm 1 240 1 245 Float 1 235 1 250 1240 s cen Dead 22 26 7 C 909 9 d E E P Replace Batte 1 240 1 245 notrise 1 235 1 250 1 240 p y Page 10 12 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD Test Proce
137. Power and Continuity Check of AC Circuit on page 4 13 1 Qu ui 200 2 ND Disconnect AC cord from the wall outlet Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 Remove the charger cover Disconnect transformer secondary coil wires 1 and 5 from the heatsink Figure 4 17 Page 4 18 To apply AC power directly to the transformer primary coil the relay must be bypassed 5 1 To bypass the relay remove the black wire 3 from the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 4 17 Page 4 18 See following DANGER A 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 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 17 Test Procedures POWERDRIVE CHARGER ONBOARD Test Procedures RED DIODES DC CORD BLUE WITH BLACK HEATSINK DAZ GROUND Figure 4 17 Transformer Test Wiring Diagram 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 If the AC line fuse does not blow or the AC circuit breaker does not trip check the transformer secondary coil voltage 8
138. R TEE Euse Llnk xot ect E EAA ea debe patte E ESAE AEE LETER Voltage SU ppressOEF rn riter et tu A Ee aeaa LEa ee REIR RA RRY TAE To Ra daiwa LE LIA AERE AAEE ORRERA ESO Charger RELAY rasan ai r Ae AREE EE RTA RRS T raa aE EEA ANEA REEE ATETEA Charger AC Circuit Breaker esinin inasi raataa taa raaa AA Aa e LEA a nena a anota ARAARA Charger AC GOFG yone ari AEA aR tiet AAAA R A aA LER ee epar e Pe ATEA EEA Charging a Battery Pack that has Low Voltage semen 2008 2011 Domestic Battery Charger Maintenance and Service Manual 8 1 8 2 8 2 8 2 8 3 8 4 8 5 8 5 8 7 8 8 8 8 8 8 8 9 8 12 8 12 8 23 8 23 8 24 8 25 8 26 8 27 8 27 8 28 8 28 8 28 8 29 Page vii SECTION 9 IQ PLUS CHARGER ONBOARD General nformatiori 5 0a eei ei UR em aU cM RM GR MAREA 9 1 IQ Plus Onboard Charger Features ssssseene eene enne en nennen nnns 9 2 Battery Waning Eightt 1 otn compen tne ed ete ee ea ee ete 9 2 Uana GSA EIStQng s steeds RR edi eene te d th eee ite dee dt adus 9 2 The Charge GIreult s e rc E RE HU EUR IER ce REED pete roc ded 9 2 Onboard Charger Operation ande oaov A t e REP ERA CAM eee 9 3 Onboard Charger AC Power Connection esssssssssssseeeene eene nenereis 9 4 Charging Batteries aeg ote oie detta fiet em tee ed ee ected 9 4 Checking Battery Condition with an Onboard Charger ssssse ee 9 5 Start Charge Cycle a 3x tite often detee pet tte i ti
139. RGER AC CORD AND RETRACTABLE CORD REEL See General Warning Section 1 Page 1 1 Short AC Cord Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 2 Remove the charger cover 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 27 EN IQ PLUS CHARGER ONBOARD Charger Repairs 3 Disconnect the AC cord black wire from the AC circuit breaker Figure 9 19 Page 9 27 4 5 Disconnect the AC cord green wire from the charger base Figure 9 19 Page 9 27 6 Disconnect the AC cord white wire from the control board Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger Short AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Figure 9 19 Page 9 27 Connect the black wire to the AC circuit breaker the white wire to the control board and the green wire to the charger base Figure 9 3 Page 9 6 Tighten the screw on the green ground wire terminal to 18 in Ib 2 0 N m 3 Position the strain relief bushing on the AC cord 4 Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 9 31 Check charger for proper opera
140. S 1 D DC CORD BLUE P WITH BLACK PRIMARY COIL GROUND Figure 4 26 PowerDrive Onboard Charger Wiring Diagram Relay Bypassed Page 4 32 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Onboard Charger Removal and Installation ONBOARD CHARGER REMOVAL AND INSTALLATION See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 4 Page 4 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 DS VILLAGER 4 Onboard Charger Removal 1 Connect the batteries See Connecting The Batteries on page 1 4 2 Remove four bolts 21 flat washers 22 lock washers 23 and nuts 24 from charger mounting brack ets Figure 4 27 Page 4 33 Figure 4 27 Onboard Charger Mounting DS Villager 3 Remove 10 gauge black charger DC cord wire 19 from the charger receptacle fuse link Figure 4 28 Page 4 34 4 Remove 10 gauge red charger DC cord wire from the positive post of battery no 1 See Section 1 General Warning 5 Disconnect the 10 gauge charger DC cord blue wire 17 from the 3 way wire adapter 18 at the sense lead fuse 20 Figure 4 28 Page 4 34 6 Cut any wire
141. Section 1 Page 1 1 See additional WARNING on page 8 1 AC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 8 15 Page 8 20 4 Disconnect the black wire 1 of AC cord from charger AC circuit breaker 3 5 Disconnect the AC cord white wire 4 from the primary coil tan wire 6 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced 7 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug Figure 8 15 Page 8 20 The tester should indicate continuity on only the round pin If any other reading is obtained the AC cord and plug must be replaced 8 Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only one flat blade If any other read ing is obtained the AC cord and plug must be replaced 200 OHM SETTING Figure 8 15 AC Cord and Plug Cont
142. Set the park brake Turn the key switch OFF and remove the key Place the Forward Reverse control in the NEUTRAL position In addition chock the wheels if servicing or repairing the vehicle DISCONNECTING THE BATTERIES Disable the vehicle See Disabling The Vehicle on page 1 3 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury 3 Disconnect the batteries negative cable first as shown Figure 1 1 through Figure 1 8 4 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 1 3 General Warning SAFETY General Warning CONNECTING THE BATTERIES 1 Ensure the Tow Run switch is in the TOW position 2 Connect the battery cables positive cable first 3 Tighten battery terminals to 110 in Ib 12 4 N m 4 Coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion Figure 1 1 Precedent Battery Configuration Style A Figure 1 2 Precedent Battery Configuration Style B 4 x 12 Volt Batteries 4 x 12 Volt Batteries Viewed from driver side of vehicle Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables connect
143. T IQ Plus vehicles feature a dash mounted battery warning light above the steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charg ing problem The battery warning light is controlled by the onboard computer When the batteries receive an incomplete charge because 1 AC power to charger is interrupted 2 automatic charger shut off occurs after 16 hours of operation or 3 charger malfunctions the battery warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger AC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer UL AND CSA LISTING
144. T See General Warning Section 1 Page 1 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and then reconnect it The ammeter should jump to a reading between 14 and 18 amps and then taper to below 5 amps within 15 minutes 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Control Board on page 9 11 See following NOTE NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Section 13 Batteries in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 Short AC Cord and Retractable Cord Reel Check continuity of the short AC cord and retractable cord reel at the same time 1 Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 3 Remove the charger cover 4 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 9 12 Page 9 18 c1 Disconnect the black wire 1 of the short AC cord from charger AC circuit breaker 6 Disconnect the AC cord white wire 4 from the control board 7 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the
145. Test Probes Reversed DIODE SETTING Page 7 22 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Test Procedures 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 A DANGER Do not touch any wire or component in the battery charger while AC power is p
146. The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the charger recepta cle If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check wire continuity and connections between the charger receptacle onboard computer and batteries Page 6 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 The Charge Circuit EN CHARGER FRONT RECEPTACLE OF VEHICLE AN HO 8Lit x o m E 8 SINGLE POSITION CONNECTOR ONBOARD COMPUTER SOLID STATE SPEED CONTROLLER Figure 6 6 Charge Circuit and Style C Battery Configuration 6 x 8 Volt Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 7 ES POWERDRIVE 3 MODEL 26560 Charger Installation and Operation CHARGER INSTALLATION AND OPERATION See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the
147. WERDRIVE 2 CHARGER EXTERNAL Troubleshooting Use the following Troubleshooting Guide for troubleshooting PowerDrive 2 external battery chargers model numbers 22110 11 22110 18 and 22110 19 The Troubleshooting Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages POWERDRIVE 2 BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected See Section 13 Batteries in the appropriate maintenance and service manual Battery voltage is too low Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 13 Poor connection between plug and receptacle Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 13 DC plug and cord Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 13 and Test Procedure 5 Charger DC Circuit Continuity Test on page 5 17 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 15 Gray sense lead fuse is blown not applicable to Precedent vehicles Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 13 Receptacle fuse link is blown not applicable to Precedent vehicles See Section 12 Electrical Components in the appropriate maintenance and s
148. ace 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 indicates 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 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 25 POWERDRIVE 3 MODEL 26580 Test Procedures Transformer The PowerDrive 3 battery charger transformer has two sets of coils a primary coil and a secondary coil Figure 7 10 Page 7 15 Primary Coil 1 2 3 Disconnect AC cord 6 from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan pri mary coil wire and disconnect the white wire 4 Figure 7 22 Page 7 25 4 Disconnect the black primary coil wire 5 from the relay Figure 7 22 Page 7 25 5 Place the continuity tester probes on the disconnected primary coil wires The tester should indicate con tinuity If tester does not indicate continuity replace the transformer If the correct readings were obta
149. ace 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 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 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 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove the transformer tan secondary coil wire 1 from the upper terminal of the heatsink Figure 3 22 Page 3 23 Remove the other transformer tan secondary coil wire 5 from the bo
150. age 1 1 See additional WARNING on page 8 1 Charger Relay Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect all wires from the relay Figure 8 19 Page 8 29 4 Remove two nuts and lock washers attaching relay to the charger case 5 Remove the relay Charger Relay Installation 1 Install in reverse order of removal Connect wires as shown Figure 8 19 Page 8 29 Tighten nut secur ing relay to charger base to 18 in Ib 2 0 N m CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 AC Circuit Breaker Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the two black wires attached to the AC circuit breaker Figure 8 19 Page 8 29 4 With a pair of pliers squeeze in the retaining tabs on the sides of the AC circuit breaker and remove the circuit breaker through the mounting hole in the face of the charger AC Circuit Breaker Installation 1 Install in reverse order of removal CHARGER AC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 AC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the AC cord black wire from the AC circuit breaker Figure 8 19 Page 8 29 Disconnect the AC cord white
151. ained the AC cord and retractable cord reel must be tested inde pendently of each other 10 Disconnect the AC cord white wire 4 from the control board Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord and retractable cord reel must be tested independently of each other 11 Ifthe correct readings are obtained in all of the previous steps the short AC cord is functioning properly Proceed to the following test procedure to test the retractable cord reel Retractable Cord Reel Check continuity of the AC cord and retractable cord reel at the same time 1 Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 3 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 4 19 Page 4 20 4 Disconnect the short AC cord from the retractable cord reel 5 Using a multimeter set for 200 ohms place the red probe in one of the flat blade openings of the cord reel receptacle 1 Figure 4 21 Page 4 22 Test for continuity at the cord reel AC plug 2 on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any othe
152. aining three rectifier terminals and note the readings Figure 6 19 Page 6 20 The multimeter should indicate an overload no continuity for all three of the remaining rectifier terminals If any other reading is indicated the rec tifier has failed and must be replaced 6 Onrare occasions the rectifier may fail as a result of a lightning strike at the charging location 7 Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION f connections are not clean and tight excessive heat will be created and the charger may become damaged TEST PROCEDURE 5 CHARGER DC CIRCUIT CONTINUITY TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 1 Disconnect the AC cord from the wall outlet and the DC cord from the vehicle charger receptacle 2 Using a multimeter set to the diode test function place the positive probe of the multimeter on the pin marked positive on the DC plug Figure 6 20 Page 6 21 Place the negative probe on the pin marked negative The multimeter should indicate an overload no continuity POSITIVE PIN DIODE gt SETTING Figure 6 20 DC Plug Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 21 E POWERDRIVE 3 MODEL 26560 Test Procedures 3 Reverse the test probes and check the DC plug again Figure 6 21 Page 6 22 The mult
153. ait 20 seconds then reconnect the AC cord to the wall outlet See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed Page 4 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Troubleshooting 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 4 Page 4 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 Use the following Troubleshooting Guide for troubleshooting export PowerDrive onboard battery chargers model numbers 17935 10 and 17935 40 The Troubleshooting
154. al injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 1 With the charger DC cord disconnected from the vehicle charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 8 3 Page 8 7 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected See following WARNING A WARNING Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 8 3 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge r
155. an 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 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 21 EN IQ PLUS CHARGER EXTERNAL Test Procedures Voltage Suppressor Failed Closed 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Using a multimeter set to the diode test function place the black probe of the multimeter on the 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 NOTE Repeated failure of sense lead fuses is a symptom of a voltage supressor that has failed in a closed condition Relay 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove black 3 and tan 4 wires from contact terminals of the relay Figure 8 14 Page 8 19 Place continuity test probes on contact terminals of the relay The tester should indicate no continuity If tester indicates continuity the relay contacts have failed closed and the relay must be replaced 4 Pla
156. an 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a charge for an entire work shift However discharge time is dependent on the elec trolyte temperature The table shown gives the discharge times at various temperatures of a set of bat teries that delivers 62 minutes at 80 F 26 7 C ELECTROLYTE DISCHARGE TIME TO ELECTROLYTE DISCHARGE TIME TO TEMPERATURE SHUT OFF POINT TEMPERATURE SHUT OFF POINT 40 49 F 85 89 F 4 9 C 40 Minutes 29 32 C 64 Minutes 50 59 F 89 99 F 10 15 C 45 Minutes 32 37 C 66 Minutes 60 64 F 100 109 F A 16 18 C 50 Minutes 38 43 C 68 Minutes 65 69 F 110 119 F 18 21 C 54 Minutes 43 48 C 70 Minutes 70 74 F 120 129 F 21 23 C 57 Minutes 49 54 C 72 Minutes 75 79 F 130 150 F 24 26 C 60 Minutes 54 66 C 74 Minutes 80 84 F i kkkkk kkkkk 27 29 C 62 Minutes Page 10 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD Interpreting Discharge Test Results 8 Volt Batteries 1 If discharge time is 60 minutes or higher the problem is not with the batteries Test Procedures 2 If discharge times are low less than 60 minutes replace batteries below 6 7 volts BATTERY VOLTAGES BATTERY CONDITION 1 2 3 4 5 6 7 00V 7 00 V 7 00 V 7 00 V 7 00 V 7 00V Excellent 7 07 V 7 07 V 7 22V
157. and make sure that the vehicle is wired correctly Figure 7 3 Page 7 4 and that the internal charger wiring is correct Figure 7 9 Page 7 11 TRANSFORMER TOP SIDE DIODE DIODE ASSEMBLY ASSEMBLY TAN TAN VIOLET PRIMARY AC CORD AC CIRCUIT BREAKER ST nec p BLACK CASE GROUND 100 Ohm RELAY BOARD ASSEMBLY WITH SUPPRESSOR Figure 7 9 PowerDrive 3 Battery Charger Wiring Diagram External Charger DC CORD AND PLUG INSPECTION The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See Charger Receptacle in Section 12 of the appropriate maintenance and service manual for receptacle removal and installation See also DC Cord Removal on page 7 28 See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 11 POWERDRIVE 3 MODEL 26580 Checking Battery Condition After a charge Cycle CHECKING BATTERY CON
158. and plug the AC cord into an electrical outlet 11 Allow the charger to continue charging the batteries until the charger shuts off automatically 12 When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual TRANSFORMER TOP SIDE DIODE DIODE ASSEMBLY ASSEMBLY LET WHITE TAN TAN VIO GREEN b BLACK PRIMARY SECONDARY AMMETER DC CORD AC CIRCUIT COIL COIL RED AC CORD BREAKER NEG A gt T BLACK TAN ORANGE id z F BLACK PER d GROUND 100 Ohm RELAY BOARD ASSEMBLY WITH SUPPRESSOR Figure 7 25 PowerDrive 3 Charger Wiring Diagram Relay Bypassed 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 35 SECTION 8 IQ PLUS CHARGER EXTERNAL A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 The battery charger DC plug must be pulled slowly from the receptacle Figure 8 3 Page 8 7 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode F
159. are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See Charger Receptacle in Section 12 of the appropriate maintenance and service manual for receptacle removal and installation See also DC Cord Removal on page 6 27 See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 11 ES POWERDRIVE 3 MODEL 26560 Checking Battery Condition After a charge Cycle CHECKING BATTERY CONDITION AFTER A CHARGE CYCLE See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ System PowerDrive and Excel System vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located a
160. arged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CC P N 101831801 See Communication Display Module in the appropriate maintenance and ser vice supplement If charger does not appear to be operating properly or if the batteries appear to be weak contact your Club Car distributor dealer Page 7 10 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Charger Installation and Operation TESTING CHARGER OPERATION 1 With the DC plug disconnected from the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 2 Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle The charger relay should close with an audible click after a 2 to 15 second delay See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 7 2 3 If the charger does not operate exactly as described above refer to the wiring diagram
161. arger malfunction property damage or severe personal injury 7 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m HEATSINK See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Heatsink Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove both secondary coil transformer wires tan from the heatsink Figure 3 9 Page 3 11 and Figure 3 10 Page 3 15 4 Remove the two red wires from the heatsink 5 Remove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Place heatsink against charger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts that secure the heatsink to the case Tighten the bolts to 18 in Ib 2 0 N m Figure 3 9 Page 3 11 and Figure 3 10 Page 3 15 2 Connectthe red wire from the DC cord and the red wire from the charger relay to the center terminal post on the heatsink Tighten nut to 18 in Ib 2 0 N m Page 3 28 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Charger Repairs 3 Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 4 Connect the other secondary coil transformer wire tan to
162. arger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 8 15 Charger failure See Testing Charger Operation on page 8 8 16 hour time out See Battery Warning Light on page 8 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Battery warning light illuminates for ten seconds at four second intervals with DC charger cord unplugged Batteries are getting close to full discharge capacity Recharge batteries golf round may be completed first Onboard computer malfunction Test Procedure 2 Onboard Computer on page 8 15 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 11 EN IQ PLUS CHARGER EXTERNAL PRIMARY COIL RED WIRE OF DC CORD RED WIRE TO RELAY SECONDARY COIL WIRES TAN SECONDARY COIL WIRES BLACK DC CORD BLACK WIRE TO AMMETER Figure 8 6 IQ Plus Battery Charger TEST PROCEDURES GREEN GROUND WIRE BLACK WIRE TO CIRCUIT BREAKER BLACK WIRE TO RELAY Te
163. at insulates the AC cord white wire 4 where it connects to the tan pri Disconnect the AC cord black wire 1 from the AC circuit breaker 3 Figure 7 22 Page 7 25 mary coil wire Figure 7 22 Page 7 25 Disconnect the AC cord white wire 4 from the primary coil tan wire Disconnect the AC cord green wire 2 from the charger base Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger AC Cord Installation 1 Ov 4m o M Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Connect the AC cord black wire 1 to the AC circuit breaker 3 Figure 7 22 Page 7 25 Place a piece of heatshrink tubing 7 over the AC cord white wire 4 Connect the AC cord white wire 4 to the tan primary coil wire Figure 7 22 Page 7 25 Slide the heatshrink tubing 7 over the connection and apply heat to the heatshrink to insulate the con nection between the AC cord white wire 4 and the tan primary coil wire See following WARNING A WARNING Make sure the electrical connections are properly insulated Failure to properly insulate electrical connections in the charger could result in a short circuit Connect the green wire 2 to the charger base Tighten the screw and nut on the green ground wire terminal to 18 in Ib 2 0 N m Position the strain relief bushing on the AC cord Using pliers install the strain
164. ate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diag nostic program ammeter will drop to zero See following NOTE NOTE Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge between charges until the bat teries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries use the CDM Communication Display Module CC P N 101831801 See Communication Display Module in the appropriate main tenance and service supplement Page 8 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER
165. atteries Set the multimeter to 200 volts DC Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 for 4 x 12 volt battery set battery no 6 for 6 x 8 volt battery set or battery no 8 for 8 x 6 volt battery set Record reading Then set multimeter to 20 volts DC and place the red probe on the positive post and the black probe at the negative post of each battery Record the readings The on charge voltage for the set should be between 56 0 volts and 63 0 volts depending on the age and state of charge of the batteries being tested Page 10 10 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD Test Procedures For 6 volt batteries If individual batteries read above 7 0 volts and are within 0 5 volts of each other go to the hydrometer test flooded lead acid batteries or discharge test gel cell or AGM batteries If any battery reads below 7 0 volts and not within 0 5 volts of those batteries above 7 0 volts replace battery If readings are below 7 0 volts but within 0 5 volts of each other the batteries are old For 8 volt batteries If individual batteries read above 9 3 volts and are within 0 7 volts of each other go to the hydrometer test flooded lead acid batteries or discharge test gel cell or AGM batteries If any battery reads below 9 3 volts and not within 0 7 volts of those batt
166. aving recorded the amount of energy consumed as the vehicle was used directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies Figure 5 1 PowerDrive 2 Battery Charger 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 1 E POWERDRIVE 2 CHARGER EXTERNAL General Information POWERDRIVE 2 BATTERY CHARGER FEATURES Charge Interlock PowerDrive 2 battery charger DC plugs have three pins rather than two blades common on most stan dard charger plugs Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead that is the communication link between the charger and the onboard com puter When the charger plug is plugged into the vehicle receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge IQ System PowerDrive and Precedent vehicles with PowerDrive 2 chargers are designed to be left connected with AC power to the charger during off season storage The onboard computer will auto matically activate the charger every 15 days To re
167. battery charging cir cuit Test procedures specified in the Troubleshooting Guide can be found on the following pages IQ PLUS ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected Connect the batteries See Connecting The Batteries on page 1 4 Battery voltage is too low Test Procedure 1 Battery Voltage on page 9 9 Improper vehicle or battery charger wiring See Figure 9 2 Page 9 3 Figure 9 3 Page 9 6 and Figure 9 4 Page 9 10 DC circuit Test Procedure 5 Charger DC Circuit Continuity Test on page 9 14 Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Gray sense lead fuse is blown Test Procedure 1 Battery Voltage on page 9 9 Control board malfunction Test Procedure 2 Control Board on page 9 11 Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC line voltage Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 9 12 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 9 12 Failed AC cord reel Test Procedure 8 Continuity on page 9 17 Internal AC breaker Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 9 12 Transformer primary coil
168. battery voltage approximately 47 50 volts If reading is incorrect replace control board AC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and blue wires remain connected to vehicle Set multimeter to volts AC 2 Disconnect tan wire from transformer primary coil at terminal on control board Figure 4 11 Page 4 13 See following DANGER A 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 Page 4 12 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Test Procedures 3 Place black probe of multimeter set to 200 volts AC onto terminal with black AC circuit breaker wire Connect red probe to terminal from which tan transformer wire was disconnected Figure 4 10 Page 4 12 4 Connect AC cord to outlet Reading should be approximately 110 to 128 volts AC 5 If reading is incorrect replace control board BLACK WIRE TO RELAY BLACK WIRE TO AC CIRCUIT f BREAKER BLUE WIRE TO RELAY 2 TAN WIRE TO TRANSFORMER p PRIMARY COIL RED WIRE TO RELAY SF U I V WHITE WIRE TO AC CORD cig amp wae U j Let RED WIRE D TO HEATSINK BLUE WIRE TO DC CORD Figure 4 11 Control Board TEST PROCEDURE 3 AC POWER AND CONTINUITY CHECK OF AC CIRCUIT See General Warning Section 1 Page 1 1 1 Disconnect the AC power supply cord from the
169. black wire 1 Figure 9 12 Page 9 18 Test for continuity on each of the flat blades and then on the round pin of the AC plug on the retractable cord reel The tester should indicate continuity on one flat blade only If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 8 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug on the retractable cord reel Figure 9 12 Page 9 18 The tester should indicate continuity on only the round pin If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 9 Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug on the retractable cord reel The tester should indicate continuity on only one flat blade If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 10 Ifthe correct readings are obtained in all of the previous steps the short AC cord and the retractable cord reel are functioning properly If any of the readings are incorrect proceed to the following test procedures to determine which of the two components has failed 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 17 EN IQ PLUS CHARGER ONBOARD
170. black wire of the DC cord from the ammeter Figure 9 16 Page 9 22 4 Disconnect the red wire of the DC cord from the heatsink 5 Disconnect the blue wire from the control board 6 Using a multimeter set for 200 ohms place the red probe on the red wire of the DC cord Test for con tinuity on each of the wires on the other end of the DC cord The tester should indicate continuity on the red DC cord wire only If any other reading is obtained the DC cord must be replaced Place the red probe on the blue wire of the DC cord Test for continuity on each of the wires on the other end of the DC cord The tester should indicate continuity on the blue DC cord wire only If any other reading is obtained the DC cord must be replaced Place the red probe on the black wire of the DC cord Test for continuity on each of the wires on the other end of the DC cord The tester should indicate continuity on the black DC cord wire only If any other reading is obtained the DC cord must be replaced Page 9 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Test Procedures EN Transformer The IQ Plus battery charger transformer has two sets of coils a primary coil and a secondary coil Primary Coil 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 2 Remove the charger cover 3 Disconnect terminals from transformer tan
171. bove the steering column in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual appropriate for your battery charger If you do not have this publication contact your Club Car representative If the specified test procedures identify no problems plug the DC cord into the vehicle and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle charger receptacle 2 Wait 20 seconds then reconnect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the vehicle has been driven even if only a few feet the onboard computer will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle continues If the batteries are close to being fully charged the charge cycle will begin and the charge cur
172. ce continuity test probes on contact terminals of relay With batteries connected insert DC plug into receptacle The tester should indicate continuity If tester does not indicate continuity relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the black wire from the left ammeter post as viewed from inside the charger 4 Place the continuity tester clip on one of the ammeter posts 5 Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker Tw Geo ino Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the wires from the AC circuit breaker Place the continuity test probes on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuity replace the AC circuit breaker Page 8 22 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Charger Repairs EN CHARGER REPAIRS See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 8 5 Page 8 9 Prior to servicing the charger disconne
173. cedure 1 Battery Voltage and DC Plug and Receptacle on page 3 16 Receptacle fuse link is blown not applicable to Precedent vehicles See Electrical Components section in the appropriate maintenance and service manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Internal AC breaker Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Transformer primary coil Test Procedure 6 Transformer on page 3 22 Relay Test Procedure 8 Continuity on page 3 24 Failed ammeter Replace ammeter Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 4 Diodes on page 3 20 Both Diodes failed Test Procedure 4B Both Diodes Failed on page 3 21 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 19 Failed transformer Test Procedure 6 Transformer on page 3 22 Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 3 24 Single charger fuse
174. cep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD ER M SOLID STATE COMPUTER E SPEED CONTROLLER FUSE LINK N 10 BLACK a 6 BLACK TN 7a CHARGER HOBLACK c RECEPTACLE N I 10 BLACK We 18 GRAY IN 8 GRAY NIJ 10 RED SENSE LEAD FUSE Figure 3 2 Charge Circuit and Battery Configuration DS DS Villager 4 800 810 and 850 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 3 E POWERDRIVE CHARGER EXTERNAL The Charge Circuit TURF 1 AND CARRYALL 1 The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 3 Page 3 4 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one
175. 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 AC cord reel internal AC circuit breaker and charger wiring See Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 9 12 1 Disconnect AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 3 Remove the charger cover 4 Disconnect transformer secondary coil wires 1 and 5 from the heatsink Figure 9 11 Page 9 16 5 To apply AC power directly to the transformer primary coil the relay must be bypassed 5 1 To bypass the relay remove the black wire 3 from the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 9 11 Page 9 16 See following DANGER A 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 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 15 9 IQ PLUS CHARGER ONBOARD Test Procedures DC CORD WITH HEATSINK TRANSFORMER Figure 9 11 Transformer Test Wiring Diagram Make sure the secondary coil wires are not touching one another With the relay bypassed insert the AC plug into an outlet If
176. circuit or the circuit may become overloaded See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances The AC power cord must be a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress CHARGING BATTERIES NOTE Batteries should be put on charge even if they have been used for only a short time i e 10 min utes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak contact a local Club Car distribu tor dealer New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charg
177. coil and a secondary coil Figure 6 10 Page 6 15 Primary Coil 1 Disconnect AC cord 6 from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan pri mary coil wire and disconnect the white wire 4 Figure 6 22 Page 6 24 4 Disconnect the black primary coil wire 5 from the relay Figure 6 22 Page 6 24 5 Place the continuity tester probes on the disconnected primary coil wires The tester should indicate con tinuity If tester does not indicate continuity replace the transformer 6 Ifthe correct readings were obtained install the AC cord and connect the transformer primary coil wires See AC Cord Installation on page 6 33 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 black secondary coil wires 1 and 2 from the rectifier Figure 6 9 Page 6 11 4 Place the continuity tester probes on the disconnected secondary coil wires The tester should indicate continuity If tester does not indicate continuity replace the transformer 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 25 E POWERDRIVE 3 MODEL 26560 Test Procedures Voltage Suppressor Failed Closed The voltage suppressor which is incorporated into the relay board assembly protects the
178. connection of the 10 gauge black wire from the onboard computer and the 10 gauge black wire from the battery charger at the fuse link on the charger receptacle 1 3 Check the connections of the DC cord blue wire 17 from the charger and the gray wire from the onboard computer to the the 3 way wire adapter 18 Figure 4 28 Page 4 34 See following WARNING A WARNING Do not bypass the sense lead fuse 1 4 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistance should be less than 2 ohms 2 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 4 5 Page 4 10 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 34 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 4 31 Figure 4 5 Battery Voltage Test DS Villager 4 Test Procedure 1B Precedent Vehicles 1 Check the wire connections between the vehicle and battery charger Figure 4 3 Page 4 3 1 1 Verify that the 10 gauge red wire of the charger is connected to the positive post of battery no 1 1 2 Verify the connection of the 10 gauge black wires
179. continuity at the cord reel AC plug 2 on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the cord reel must be replaced 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 19 9 IQ PLUS CHARGER ONBOARD Test Procedures 200 OHM SETTING Figure 9 15 Retractable Cord Reel Test Place the red probe into the other flat blade opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the cord reel must be replaced Place the red probe into the top center opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on only the round pin If any other reading is obtained the retractable cord reel must be replaced 8 If the correct readings are obtained in all of the previous steps the retractable cord reel is functioning properly DC Cord 1 Disconnect the AC cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the
180. 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 IQ Plus battery charger transformer has two sets of coils a primary coil and a secondary coil Figure 8 14 Page 8 19 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 8 14 Page 8 19 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 8 14 Page 8 19 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 8 14 Page 8 19 Test for continuity between the buss bar and each of the secondary coil wires t
181. corner when viewed from the front of the charger 2 Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 3 26 Page 3 30 Tighten to 22 in Ib 2 5 N m 3 Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tighten to 22 in Ib 2 5 N m 4 Install the charger cover VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 The voltage suppressor which is incorporated into a wire assembly in the charger protects the onboard com puter by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehicle See also Test Procedure 8 Conti nuity on page 3 24 Voltage Suppressor Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove nut attaching voltage suppressor 18 gauge red wire to heatsink Figure 3 27 Page 3 33 4 Disconnect the blue and red wires from the relay 5 Disconnect the DC cord blue wire at the quick disconnect terminal 6 Remove the voltage suppressor and wire assembly from the charger Voltage Suppressor Installation 1 Install in reverse order of removal Tighten nut attaching voltage sup
182. ct the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 8 17 Page 8 23 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink Remove the wire tie that secures the DC cord wire to the secondary coil wire tan Remove the wire tie on the DC cord near the strain relief bushing Noc A Disconnect the DC cord blue wire from the red wire assembly that connects to the charger relay Figure 8 16 Page 8 23 8 Using pliers squeeze the strain relief bushing and remove the DC cord Figure 8 16 Page 8 23 DC CORD BLUE WIRE eu ABE R TO RED WIRE ASSEMBLY LAC AT RELAY TO AMMETER p N ea E nae STRAIN RELIEF BUSHING Figure 8 16 DC Cord Figure 8 17 DC Cord Replacement 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 23 EN IQ PLUS CHARGER EXTERNAL Charger Repairs DC Cord Installation 1 2 3 4 Insert the leads of the new DC cord through the hole in the charger base Attach the red wire of the new DC cord to the center termi
183. ctifier Figure 5 6 Page 5 8 8 Using a 1 8 inch 3 mm drill bit drill the rivets that secure the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with primary coil to the rear of the charger case Secure the transformer to the case with two rivets 2 Connect the two black secondary coil transformer wires 1 and 5 to the AC terminals of the rectifier Figure 5 6 Page 5 8 Connect the black transformer primary coil wire 4 to the charger relay Place a piece of heatshrink tubing over the AC cord white wire Connect the AC cord white wire to the tan primary coil wire Figure 5 17 Page 5 20 oo e w Slide the heatshrink tubing over the connection and apply heat to the heatshrink to insulate the connec tion between the AC cord white wire and the tan primary coil wire See following WARNING A WARNING e Make sure the electrical connections are properly insulated Failure to properly insulate electrical connections in the charger could result in a short circuit 7 Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING e Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 8 Install the charger cover and check charger for proper operation AMMETER See General Warning Section 1 Page 1 1 Se
184. d Style A Battery Configuration 4 x 12 Volt Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 5 POWERDRIVE 3 MODEL 26580 The Charge Circuit CHARGER RECEPTACLE 0 J z COMPUTER Figure 7 5 Charge Circuit and Style B Battery Configuration 4 x 12 Volt Precedent Vehicles PRECEDENT VEHICLES 6 X 8 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 7 6 Page 7 7 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the charger recepta cle If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check wire continuity and connections between the charger receptacle onboard computer and batteries Page 7 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 The Charge Circuit KS CHARGER FRONT RECEPTACLE OF VEHICLE ANHO
185. d computer is con nected to the charger receptacle If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check wire continuity and connections between the charger receptacle onboard computer and batteries BATTERY BANK co 0 b z MOV1E OL SINGLE POSITION CONNECTOR ONBOARD COMPUTER CONTROLLER Figure 3 4 Charge Circuit and Style A Battery Configuration 4 x 12 Volt Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 5 E POWERDRIVE CHARGER EXTERNAL The Charge Circuit CHARGER RECEPTACLE 0 J z COMPUTER Figure 3 5 Charge Circuit and Style B Battery Configuration 4 x 12 Volt Precedent Vehicles PRECEDENT 6 X 8 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 6 Page 3 7 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the c
186. d good electrical contact See Charger Receptacle in Section 12 of the appropriate maintenance and service manual for receptacle removal and installation See also DC Cord Removal on page 3 27 See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 11 POWERDRIVE CHARGER EXTERNAL Checking Battery Condition After a Charge Cycle CHECKING BATTERY CONDITION AFTER A CHARGE CYCLE See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ System PowerDrive and Excel System vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual appropriate for your battery charger If you do not have this publication contact your Club Car representative If the specified test procedures identify no problems plug the DC cord into the vehicle and let it charge until the charger shuts
187. d 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 Ifthe 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 6 21 11 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and then reconnect it The ammeter should jump to a reading between 12 and 14 amps and then taper to below 5 amps within 15 minutes 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Onboard Computer on page 6 19 NOTE Batteries near the end of their useful lives may not allow the battery charge current to tap
188. death 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 23 POWERDRIVE 3 MODEL 26580 Test Procedures TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and then reconnect it The ammeter should jump to a reading between 12 and 14 amps and then taper to below 5 amps within 15 minutes 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Onboard Computer on page 7 19 NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Section 13 Batteries in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 Fuse 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord black wire from the fuse and position it so it does not touch any metal part of the charger Figure 7 10 Page 7 15 4 Using a multimeter set for 200 ohms place the red probe on one fuse terminal and the black probe on the other fuse terminal The tester should indicate continuity If the tester does not
189. der to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer having recorded the amount of energy consumed as the vehicle was used directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 1 POWERDRIVE 3 MODEL 26580 General Information POWERDRIVE 3 BATTERY CHARGER FEATURES Charge Interlock PowerDrive 3 battery charger DC plugs have three pins rather than two blades common on most standard charger plugs Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead that is the communication link between the charger and the onboard computer When the charger plug is plugged into the vehicle receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger See following WARNING Long Term Storage Charge Vehicles with PowerDrive 3 chargers are designed to be left connected with AC power to the charger durin
190. diode mounting plate and the black test probe to a diode terminal and note the reading Figure 8 10 Page 8 17 Reverse test probes and check each diode again and note the reading Figure 8 11 Page 8 17 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 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 Ib 2 5 N m Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION If connections are not clean and tight excessive heat will be created and the charger may become damaged Page 8 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Test Procedures EN DISCONNECTED SECONDARY COIL Figure 8 10 Diode Test Figure 8 11 Diode Test Probes Reversed Test Procedure 4B Both Diodes Failed See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 To check the diodes use Test Procedure 4A Single Diode Failu
191. ds tenue deside Dee dae aate Dade aed 7 1 PowerDrive 3 Battery Charger Features ssssssssssseeeeenee eene 7 2 Battery Warning Light 32i eto e E et i 7 2 The Charge Crett 2 niente rrr p ERREUR ERREUR Ar Tee red n gute eet ae 7 3 DS 800 810 and 850 Vehicles 4 x 12 Volt eeeessssssesesssssseeennenenee nennen nennen 7 3 Turf 1 and Carryall 1 Vehicles 6 x 8 Volt sssssssssse eee 7 4 Precedent Vehicles 4 x 12 Volt eeeeesseseseeissseeeee sitne nena tentant nnns nth nnn 7 5 Precedent Vehicles 6 x 8 Volt sssssssssesssseeeeeeeeneenen ennemi nennen ener 7 6 Charger Installation and Operation ssssssssseneene eene nnnm nennen nne 7 8 AG Power GCOnnection 5 5 aite eae ated nieuama datu 7 9 Charging Batteries 7 9 Testing Charger Operation c cccceeescnceeedeeeneeeedeeeneeedeaceneeeeeeauaeeeeeeneeeeeeedenenaeeedeneeeeedeceeneeeede 7 11 DC Cord and Plug Inspection sssssssssseseeeeeene nennen nennen nnne nenne nnns 7 11 Checking Battery Condition After a charge Cycle sss 7 12 Start Charge Cy Chey sis avec ines sce e t T E EATA 7 12 TOUDIGSNOOUING dc TE 7 12 Test Procedures cathe bte eie agat abre 7 16 Index oF TestProcedureS ctii dis e A uad Eo ene AA Mo docu eot lado oet on nido dee ce LAE LOUN tals is 7 16 Relay Board Assembly 5 3 t rte oce le cuz E bed eee de e sat phases aei pd tec
192. dures Interpreting the Results of the Hydrometer Test 8 Volt Batteries The approximate state of charge can be determined from the following table SPECIFIC GRAVITY TER EMRERAIURE STATE OF CHARGE CORRECTED 1 250 1 280 100 1 220 1 240 75 1 190 1 210 50 1 160 1 180 25 If the difference between the cells is 0 020 or more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery with the low cell should be replaced CORRECTED SPECIFIC GRAVITY VEHICLE BATTERY ELECTROLYTE CORRECTION REQUIRED NO NO TEMPERATURE FACTOR CELL 1 CELL 2 CELL 3 CELL 4 ACTION 4 275 0 024 1 280 0 024 1 280 0 024 1 280 0 024 Sound Battery 12 1 20 F 6 6 C 20 024 1 251 1 256 1 256 1 256 Fully Charged Discharged JE 8 90 F 32 2 C cup 1 185 0004 1 165 0 004 1 160 0 004 1 165 0 004 en i 1 Recharge 54 3 50 F 10 C 0 012 1290 oie i Ween Here der Sene Sato 2 call Weak no 3 1 250 0 1 255 0 1 230 0 1 250 0 69 5 80 F 26 7 C 0 000 E E E Cell Catch up 21250 21255 21230 21250 Chere Discharged 4 200 0 008 1 180 0 008 1 170 0 008 1 180 0 008 Battery 38 2 100 F 37 8 C 0 008 1 208 1 188 1 178 1 188 Recharge and Recheck no 3 Cell Dead 22 4 80 F 26 7 C 0 000 EET ord Bs Sod E EE Rep
193. e identified contact your local Club Car dealer or distributor CHARGER MODEL PART NUMBER Se CHARGER NAME 17930 11 101802201 PowerDrive external 17930 18 101802202 Section 3 PowerDrive Charger External 17930 19 101802203 17935 10 101814301 PowerDrive onboard MA tot 814304 Section 4 PowerDrive Charger Onboard 17935 40 102546901 22110 11 101802204 PowerDrive2 22110 18 101802205 Section 5 PowerDrive 2 Charger External 22110 19 101802206 26560 11 103394401 26560 18 103394402 Section 6 PowerDrive 3 Model 26560 26560 19 103394403 PowerDrive3 26580 11 103499101 26580 18 103499102 Section 7 PowerDrive 3 Model 26580 26580 19 103499103 25730 11 102847801 IQ Plus external 25730 18 102847802 Section 8 IQ Plus Charger External 25730 19 102847803 25260 11 102837001 IQ Plus onboard 25260 50 103772401 Section 9 IQ Plus Charger Onboard 912 4852 SVPP325510 High Frequency algorithm 11 Section 10 High Frequency Charger Onboard High Frequency ipu MU S Section 10 High Frequency Charger Onboard High Frequency Mie iocis Section 10 High Frequency Charger Onboard 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 2 1 CHARGER IDENTIFICATION AND SPECIFICATIONS SPECIFICATIONS Specifications POWERDRIVE EXTERNAL CHARGER SPECIFICATIONS
194. e 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer Also check connections of the fuse link located on the charger receptacle Figure 8 2 Page 8 3 ONBOARD ae SOLID STATE COMPUTER FUSE LINK 9 SPEED CONTROLLER 10 BLACK TT se f BACK y CHARGER 10 BLACK xX RECEPTACLE RH Carryall 6 Transporter 4 and 6 Villager 6 and 8 18 GRAY 18 GRAY 4 10 RED Turf 2 and 252 SENSE LEAD FUSE Carryall 2 and 252 1 XRT 900 BATTERIES Figure 8 2 Charge Circuit 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 3 EN IQ PLUS CHARGER EXTERNAL External Charger Installation and Operation EXTERNAL CHARGER INSTALLATION AND OPERATION A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere
195. e 5 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Test Procedures Ea 4 Using a multimeter set to the diode test function place the black probe of the multimeter on the positive terminal of the rectifier Move the positive probe to each of the remaining three rectifier terminals and note the readings Figure 5 12 Page 5 16 4 1 The multimeter should indicate approximately 878 mV with the positive probe on the negative rectifier terminal 4 2 The multimeter should indicate approximately 483 mV with the positive probe on one of the AC rectifier terminals 4 3 The multimeter should indicate approximately 483 mV with the positive probe on the other AC rectifier terminal 4 4 If any other reading is obtained the rectifier has failed and must be replaced 5 Using a multimeter set to the diode test function place the black probe of the multimeter on the negative terminal of the rectifier Move the positive probe to each of the remaining three rectifier terminals and note the readings Figure 5 13 Page 5 16 The multimeter should indicate an overload no continuity for all three of the reaming rectifier terminals If any other reading is indicated the rectifier has failed and must be replaced 6 Onrare occasions the rectifier may fail as a result of a lightning strike at the charging location 7 Ensure that th
196. e 5 5 Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use Each charger should have its own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result in an electrical shock Do not use an adapter to plug charger into a two blade outlet or extension cord Extension cord or outlet must accept grounded three blade plug The use of an improper extension cord could result in fire or electric shock Chargers can ignite flammable materials and vapors Do not use near fuels grain dust solvents thinner or other flammables Keep charger dry Do not expose to rain Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blan
197. e 6 7 Charger Receptacle Figure 6 8 Incorrect DC Plug Removal AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions With charger DC output cord disconnected connect the power supply cord to an AC supply See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug It is for use on a nominal 120 volt 60 hertz circuit The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 meters Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Mount charger by setting it on a shelf wall mount with keyhole or hang securely from ceiling by the handle Do not hang charger upside down
198. e 7 23 Page 7 28 Remove the DC cord red wire from the ammeter Remove the DC cord blue wire from the relay board assembly o m ON Using pliers squeeze the strain relief bushing and remove the DC cord DC CORD BLUE WIRE TO RELAY DC CORD BLACK WIRE TO FUSE A DC CORD RED WIRE E Y TO AMMETER STRAIN RELIEF BUSHING Figure 7 23 DC Cord Page 7 28 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Charger Repairs DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base 2 Attach the red wire of the new DC cord to the ammeter Figure 7 23 Page 7 28 3 Attach the blue wire of the new DC cord to the relay board assembly 4 Attach black wire of the new DC cord to fuse Install the nut onto post of the fuse and tighten to 23 in Ib 2 6 N m See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m DIODE HEATSINK NOTE This Powerdrive 3 Model 26580 uses two diode heatsink assemblies A running change installed these two diode heatsink a
199. e E 4 6 battery warning light sssessussssss 4 2 charge circuit 5 eset 4 2 charge interlock ssessssssssss 4 2 circuit breaker installation 2 itae teet aa 4 29 remoVal a eee beh cedex 4 29 testing eee ERE e 4 23 control board TESTING 4 che eee e e 4 12 cord charger see AC cord or DC cord DC cord installatiGr sorserien cnn 4 25 removal tenen on pesi tts 4 24 TESTING ce cree 4 16 4 22 diodes charger see heatsink electrical system charge circuit lse 2 2 cinere gei oe 4 2 fuse link installation 00 0 cece cece cece cee eeeecaeeeeeeeseseaeeeeees 4 28 removal zn thee sible ett podus 4 28 heatsink installation 2 cette 4 25 temowval ipee te ore pones 4 25 testing 1 eiit edente neenon 4 14 long term storage charge 4 2 relay installation 5 oett eerte 4 28 removal 5 nag a Ga 4 28 TESTING ete Cei eder 4 23 retractable AC cord reel installatiOn 2 eR ete eui 4 30 removal inen veste 4 30 tESUNG ET 4 21 solenoid lockout ssessssssssesss 4 2 specification battery charger 2 2 test procedures 1 low battery voltage eeessses 4 10 2 control board 0 2 ceceeeeeceeeeeeeeeeeeeeeeeeeees 4 12 3 AC cord continuity check 4 13 9 AC POWER cio
200. e Failure on page 9 13 Transformer coil short circuit failure Test Procedure 6 Transformer on page 9 15 Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 9 12 Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 9 17 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 9 17 Failed transformer Test Procedure 6 Transformer on page 9 15 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals AC power interrupted Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 9 12 Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Charger failure See Testing Charger Operation on page 9 6 16 hour time out See Battery
201. e additional WARNING on page 5 1 Ammeter Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord red wire 1 and the white wires 3 and 4 from the ammeter Figure 5 20 Page 5 27 4 Press the locking tabs on each side of the ammeter and remove the ammeter by gently pushing the ammeter through the front of the charger case Page 5 26 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Charger Repairs EN Figure 5 20 Ammeter Ammeter Installation 1 Place the ammeter in position in the charger face and ensure that the locking tabs are secure Figure 5 20 Page 5 27 2 Connect the DC cord red wire 1 and the white wire 3 to the ammeter terminals 3 Install the charger cover 4 Plug the charger into the vehicle and check ammeter for proper operation FUSE LINK See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Fuse Link Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Gently press the fuse toward the transformer to remove the fuse from the mounting tab 4 Remove the two nuts securing the two black wires to the fuse terminals and remove the fuse Fuse Link Installation 1 Connectthe short black wire from the rectifier to one of the fuse terminal posts and install the nut Tighten n
202. e batteries to explode Figure 6 8 Page 6 9 CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and ensure the charger is operating correctly during storage BATTERY WARNING LIGHT IQ System and Excel System vehicles feature a dash mounted battery warning light above the steering col umn that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger DC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the fleet operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light
203. e charger is wired properly and all connections are clean and tight See following CAU TION CAUTION f connections are not clean and tight excessive heat will be created and the charger may become damaged TEST PROCEDURE 5 CHARGER DC CIRCUIT CONTINUITY TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Disconnect the AC cord from the wall outlet and the DC cord from the vehicle charger receptacle 2 Using a multimeter set to the diode test function place the positive probe of the multimeter on the pin marked positive on the DC plug Figure 5 14 Page 5 17 Place the negative probe on the pin marked negative The multimeter should indicate an overload no continuity POSITIVE PIN DIODE gt SETTING Figure 5 14 DC Plug Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 17 ES POWERDRIVE 2 CHARGER EXTERNAL Test Procedures Test Procedure 5 Charger DC Circuit Continuity Test Continued 3 Reverse the test probes and check the DC plug again Figure 5 15 Page 5 18 The multimeter should indicate approximately 878 mV 4 If multimeter readings are incorrect check the battery charger wiring Figure 5 6 Page 5 8 5 If the multimeter indicates an overload no continuity in both directions and the charger fuse is not blown individually check all connections and the continuity of
204. e continuity test probes on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuity replace the AC circuit breaker Page 3 26 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Charger Repairs EU CHARGER REPAIRS See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 3 9 Page 3 11 and Figure 3 10 Page 3 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 3 25 Page 3 27 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink Remove the wire tie that secures the DC cord wire to the secondary coil wire tan Remove the wire tie on the DC cord near the strain relief bushing N Oo Sf Disconnect the DC cord blue wire from the red wire assembly that connects to the charger
205. e cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life When temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use while cold batteries require more time to fully charge 1 Insert the onboard charger AC plug into a dedicated and properly wired AC receptacle to begin a charge cycle See Section 2 Charger Identification and Specifications NOTE Only connect ONE charger to a single 15 amp circuit or the circuit may become overloaded 2 Place the charger AC cord so it will not be stepped on tripped over or otherwise subject to damage or stress 3 Do not place items in the compartment where the battery charger is installed Locate the charger with adequate ventilation After the charger is plugged in the vehicle s control circuit is locked out preventing operation of the vehicle as well as the possibility of subsequent damage to the charger and vehicle 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 7 HIGH FREQUENCY CHARGER ONBOARD Maintenance Once the lockout is actuated the charger turns on and performs a Power On Self Test in which the Charger Information Light on the dash wi
206. e gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed space Wear a full face shield and rubber gloves when working on or near batteries Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 1 1 SAFETY General Warning A WARNING Do not leave children unattended on vehicle Only trained technicians should repair or service the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle and battery charger Check the vehicle owner s manual for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Any modification or chan
207. e 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 3 28 Page 3 34 See following DANGER A 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 DC CORD Yr zm AC CIRCUIT BREAKER SECONDARY COIL PRIMARY COIL HEATSINK a DIODES WITH Vas AMMETER TRANSFORMER Figure 3 28 PowerDrive Charger Wiring Diagram Relay Bypassed Page 3 34 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage 5 Plug the DC cord into the charger receptacle first and then plug the AC cord into an electrical outlet 6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 7 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 8 Disconnect the transformer wire 4 from AC circuit breaker and connect it to the relay Connect the short black wire 3
208. e the wire tie that secures the DC cord wire to the secondary coil wire tan T 8 Disconnect the two tan secondary coil transformer wires from the heatsink Figure 8 5 Page 8 9 and Figure 8 6 Page 8 12 Disconnect the two black secondary coil transformer wires from the fuse Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in Ib 3 2 N m Figure 8 6 Page 8 12 2 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in Ib 2 5 N m 3 Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in Ib 2 5 N m 4 Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 5 Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 6 Connect the tan primary coil transformer wire to the charger relay 7 Connect the other tan primary coil transformer wire to the white wire from the AC cord 8 Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING 9 Make sure wiring is properly routed and secured Failure to properly route and secure wirin
209. ecedent vehicles only 5 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 5 10 Page 5 14 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 5 29 Place multimeter black probe here FRONT OF VEHICLE Figure 5 10 Precedent Battery Configuration Page 5 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Test Procedures Ea TEST PROCEDURE 2 ONBOARD COMPUTER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to This will ensure that AC power is present 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Insert the DC cord from the second charger into the receptacle of the vehicle that is not charging properly 4 Ifthe second charger fails in the same manner as the first charger then the vehic
210. ecified on the charger Overheating and transformer burnout will result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use Each charger should have its own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result in an electrical shock Do not use an adapter to plug charger into a two blade outlet or an extension cord AC outlet must accept grounded three blade plug The use of an extension cord could result in fire or electric shock Do not operate a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use Chargers can ignite flammable materials and vapors Do not use near fuels grain dust solvents thinner or other flammables Keep charger dry Do not expose to rain Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger fro
211. eck no 3 Cell Dead 22 4 80 F 26 7 C 0 000 ie oan were 2 lll Replace Bat is TEST PROCEDURE 5 DISCHARGE TEST ALL BATTERIES If the previous tests have failed to identify the problem conduct a discharge test The discharge test comes closest to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage drops to 42 0 volts The discharge test is the hardest test on the batteries and the most time consuming to perform Use the bat tery discharge tester CC P N 101831901 Performing the Discharge Test 1 Be sure the batteries are fully charged and that the electrolyte level is correct in all cells 2 Connect the tester leads to the positive post of battery no 1 and negative post of battery no 4 last Style A and B 4 x 12 Volt Precedent Figure 10 5 Page 10 15 and Figure 10 6 Page 10 15 or no 6 last Style C 6 x 8 Volt Precedent Figure 10 7 Page 10 15 3 Check and record the electrolyte temperature of the battery packs Check cell no 2 second cell from positive post in each battery Page 10 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD Test Procedures 4 Reset discharge machine and turn the tester ON 5 When the batteries have been discharging for approximately 60 minutes set the discharge machine to function 3 and check battery set voltage Check voltage every 1
212. ect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove the DC cord black wire from the fuse by loosening the nut on the fuse Figure 5 18 Page 5 24 Remove the DC cord red wire from the ammeter Remove the DC cord blue wire from the blue wire located in the fiberglass sheathing 2a oN Using pliers squeeze the strain relief bushing and remove the DC cord 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 23 ES POWERDRIVE 2 CHARGER EXTERNAL Charger Repairs DC CORD BLUE WIRE TO VOLTAGE PPRESSOR WIRE TO FUSE DC CORD RED WIRE TOAMMETER STRAIN RELIEF BUSHING Figure 5 18 DC Cord DC Cord Installation gt A O N Insert the leads of the new DC cord through the hole in the charger base Attach the red wire of the new DC cord to the ammeter Figure 5 18 Page 5 24 Attach the blue wire of the new DC cord to the blue wire located in the fiberglass sheathing Attach black wire of the new DC cord to fuse Install the nut onto post of the fuse and tighten to 23 in Ib 2 6 N m See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 5 Using
213. ee Hen 7 9 tepals Lire terere che den gene 7 28 Specifications ieii enie aeiia 2 2 TESTING marna sth Ma eet a e e E Aude es 7 11 breaker charger circuit see circuit breaker charge circuit eenen 7 3 circuit breaker installation 5 3 e deste 7 33 removal sepe a 7 32 testing eere ines can ee i ene 7 27 cord charger see AC cord or DC cord DC cord inspection ee eee ee 7 11 installation cee ceeecestctteceseeeeeeeeeeeeeeeeeeeseeeeeees 7 29 removal EAR nipii eu 7 28 testing tme nU 7 21 7 25 Page i 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual INDEX diode tEStINg e E 7 20 diode heatsink installation 7 29 REMOVAL 1 eiit pecie ederet praa emp aaae 7 29 diodes charger see heatsink electrical system Charge circuit ceive eret erepto 7 3 fuse testing cuocere ctione iere a 7 24 fuse link installation REP 7 32 remoVal irt etie Dev de 7 32 long term storage charge 7 2 onboard computer Iu M 7 19 relay installation esan nyp reete ees 7 32 remoVal ente te eee ge 7 32 TOSTING s emere eR e ER Red 7 27 specification battery charger 2 2 test procedures 1 faulty receptacle connection 7 16 1 low battery voltage seeess 7 16 2 onboard computer eeeeeesess 7 19 3 AC cord continui
214. een ener 10 3 The Charge Circuit nitet ttg amer ten et Dente ei tH aestu ied Gad dees petes spen 10 4 Onboard Charger Operation ee sesati eier daa a iaa Ea eR e eaa en nemen ennemi nennen nnns 10 4 Charger DISPIS aia rt pu ptt e n E een kee 10 6 AG Power Connection eis eticcci te ccuier deco decus dade deve eae A EEEN SA Tani AEKA AAA ALEE EEN LAET sen dadedeckeusdanevenucnd 10 7 Charging Batteries x eie gebe e pte bid e e e Ete LLL REED E 10 7 Page viii 2008 2011 Domestic Battery Charger Maintenance and Service Manual MENACE TAN aO RET NEIEEN 10 8 Troubleshooting eosin e e HE EE ER EI ed ede Ee 10 9 Test Procedures sordei dide E de ee dide LL dioe dn a nade nee dd a Lo dd a eodd redd 10 10 Index of Test Procedures usii enian andi eieiei debba nbn donant bbb nha aite hd ALAA haa 10 10 Battery Troubleshooting Examples 12 Volt Batteries ssssee 10 19 Battery Troubleshooting Examples 8 Volt Batteries sssssssee ee 10 20 Battery Troubleshooting Examples 6 Volt Batteries ssssessse eene 10 21 Charger RaDa rd 10 22 Onboard Charger Removal and Installation sss 10 22 SECTION i INDEX 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page ix Pagex 2008 2011 Domestic Battery Charger Maintenance and Service Manual SECTION 1 SAFETY To ensure the safety of those servicing vehicles
215. ehicle s drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge PowerDrive chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically acti vate the charger every 15 days To return the vehicle to service disconnect the AC cord from the wall outlet wait 15 seconds and then plug the AC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before putting it into service BATTERY WARNING LIGHT The 48 volt electric vehicle features a dash mounted battery warning light that alerts the operator to any prob lems with the batteries or charging system The battery warning light is controlled by the onboard computer OBC When the batteries receive an incomplete charge because 1 AC power to charger is interrupted 2 automatic charger shut off occurs after 16 hours of operation or 3 charger malfunctions the battery warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 or more complete The onboard com puter will retain in memory the amount of charge needed to fully replenish the batteries and will com plete the charge during the next charge cycle When the charger AC cord is unplugged during a charge cycle the battery warning light will illum
216. en to 22 in Ib 2 5 N m 4 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 34 5 Check charger for proper operation CHARGER RELAY See General Warning Section 1 Page 1 1 Charger Relay Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 Remove the charger cover Disconnect all wires from the relay Figure 4 25 Page 4 29 BooN Remove two nuts and lock washers securing relay to the charger base 5 Remove the relay Charger Relay Installation Install in reverse order of removal Connect wires as shown Figure 4 25 Page 4 29 Tighten nut securing relay to charger base to 18 in Ib 2 0 N m Page 4 28 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Charger Repairs BLUE WIRE TO CONTROL BOARD BLACK WIRE TO m A Emm PRIMARY COIL 7 H 8 STRAIN RELIEF BUSHING EY WHITE WIRE FROM AC CORD ES BLACK WIRE TO CIRCUIT BREAKER d YT Figure 4 25 Charger Relay CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 AC Circuit Breaker Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 2 Remove the c
217. enance and Service Manual Page 6 1 ES POWERDRIVE 3 MODEL 26560 General Information POWERDRIVE 3 BATTERY CHARGER FEATURES Charge Interlock PowerDrive 3 battery charger DC plugs have three pins rather than two blades common on most standard charger plugs Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead that is the communication link between the charger and the onboard computer When the charger plug is plugged into the vehicle receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger See following WARNING Long Term Storage Charge Vehicles with PowerDrive 3 chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will auto matically activate the charger every 15 days To return the vehicle to service unplug the charger DC cord wait 15 seconds for the computer to reset and plug the charger back in See following WARN ING and CAUTION This will ensure the batteries are at their optimum charge prior to returning the vehicle to service A WARNING The charger plug must be pulled slowly from the receptacle Figure 6 7 Page 6 9 Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could caus
218. er and install the charger in the vehicle See Onboard Charger Installation on page 4 34 Check charger for proper operation Page 4 26 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Charger Repairs AMMETER See General Warning Section 1 Page 1 1 Ammeter Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 2 Remove the charger cover 3 Disconnect the black wire from the DC cord 5 and the buss bar 3 from the ammeter Figure 4 24 Page 4 27 4 Remove the two nuts 2 that secure the ammeter to the charger face 5 Remove the ammeter from the face of the charger Figure 4 24 Ammeter Ammeter Installation 1 Place the ammeter in position in the charger face Figure 4 24 Page 4 27 2 Install nuts 2 and tighten until ammeter is firmly secured 3 Connectthe black wire of the DC cord 5 to the left as viewed from inside the charger post of the amme ter 4 Connect the buss bar 3 from the fuse link to the right post of the ammeter Place flat washers on both sides of the buss bar 5 Thread nuts 4 onto both posts of ammeter until just past finger tight While holding the inside nut tighten the outside nut 4 1 4 turn See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened
219. er below 5 amps See Section 13 Batteries in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 Fuse 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord black wire from the fuse and position it so it does not touch any metal part of the charger Figure 6 10 Page 6 15 4 Using a multimeter set for 200 ohms place the red probe on one fuse terminal and the black probe on the other fuse terminal The tester should indicate continuity If the tester does not indicate continuity then the fuse has failed and must be replaced 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 23 a POWERDRIVE 3 MODEL 26560 Test Procedures AC Cord 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 6 22 Page 6 24 4 Disconnect the black wire 1 of AC cord from charger AC circuit breaker 3 5 Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan pri mary coil wire Figure 6 22 AC Cord and Plug Continuity Test 6 Disconnect the AC cord white wire 4 from the primar
220. er secondary coil wires 1 and 5 from the rectifier Figure 5 16 Page 5 19 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 black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 5 16 Page 5 19 See following DANGER Page 5 18 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Test Procedures Ea A 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 Ifthe AC line fuse does not blow or the AC circuit breaker does not trip check the transformer secondary coil voltage T 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 5 9 Connectthe AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 42 5 volts AC or lower for the secondary coil the transformer is shorted
221. eries above 9 3 volts replace battery If readings are below 9 3 volts but within 0 7 volts of each other the batteries are old For 12 volt batteries If individual batteries read above 14 0 volts and are within 1 0 volt of each other go to the hydrometer test flooded lead acid batteries or discharge test gel cell or AGM batteries If any battery reads below 14 0 volts and not within 1 0 volt of those batteries above 14 0 volts replace battery If readings are below 14 0 volts but within 1 0 volt of each other the batteries are old Old batteries may have enough capacity left to last several more months Go to hydrometer test flooded lead acid batteries or discharge test gel cell or AGM batteries TEST PROCEDURE 4 HYDROMETER TEST FLOODED LEAD ACID BATTERIES ONLY A hydrometer measures the specific gravity of the battery s electrolyte The higher the specific gravity the higher the state of charge of the batteries A fully charged battery should read between 1 250 and 1 280 at 80 F 26 7 C Never add acid to batteries to obtain a higher specific gravity Performing the Hydrometer Test 1 Be sure batteries have sufficient electrolyte to cover plates by approximately 1 2 inch 13 mm and are fully charged prior to beginning test If water must be added recharge the batteries before performing the hydrometer test 2 Remove the vent cap Using a battery thermometer CC P N 1011767 record electrolyte temperature of the n
222. eries to explode Figure 7 8 Page 7 9 Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use Each charger should have its own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result in an electrical shock Do not use an adapter to plug charger into a two blade outlet or extension cord Extension cord or outlet must accept grounded three blade plug The use of an improper extension cord could result in fire or electric shock Chargers can ignite flammable materials and vapors Do not use near fuels grain dust solvents thinner or other flammables Keep charger dry Do not expose to rain Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheati
223. erve you please rate this publication in the following categories Poor Fair Average Good Excellent Ease of Understanding Ease of Finding Information Clarity of Illustrations Photos Index Usability If you are reviewing a Kit Instruction were all indicated parts included in your kit Yes No o ARUN Your Comments and Suggestions Please send a copy of this page to Fax 706 228 2662 or Thank You E mail Tech Pubs clubcar com Club Cars Technical Publications Department 2008 2011 Domestic Battery Charger Maintenance and Service Manual am Ingersoll Rand Industrial Technologies pr Club Car LLC Web www clubcar com P O Box 204658 Phone 1 706 863 3000 Augusta GA 30917 4658 1 800 ClubCar USA Int l 1 706 863 3000 Fax 1 706 863 5808
224. ervice manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 15 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 15 Transformer primary coil Test Procedure 6 Transformer on page 5 18 Relay Test Procedure 8 Continuity on page 5 20 Failed ammeter Replace ammeter Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 8 Continuity on page 5 20 Failed rectifier Test Procedure 4 Rectifier on page 5 16 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 15 Failed transformer Test Procedure 6 Transformer on page 5 18 Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 5 20 Charger fuse link blows or receptacle fuse link blows Failed rectifier Test Procedure 4 Rectifier on page 5 16 Loose internal fuse connection Tighten connection Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Page 5 10 2008
225. ery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 15 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 15 Charger failure See Testing Charger Operation on page 5 7 16 hour time out See Battery Warning Light on page 5 2 Battery or batteries need to be replaced See Section 13 Batteries in the appropriate maintenance and service manual Battery warning light illuminates for ten seconds at four second intervals with DC charger cord unplugged 25 seconds at 10 second intervals for Precedent vehicles Batteries are getting close to full discharge capacity Recharge batteries golf round may be completed first Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 15 Battery or batteries need to be replaced See Section 13 Batteries in the appropriate maintenance and service manual 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 11 ES POWERDRIVE 2 CHARGER EXTERNAL Test Procedures VOLTAGE SUPPRESSOR PRIMARY COIL SECONDARY COIL WIRE ASSEMBLY BLACK WIRE TO PRIMARY COIL WHITE WIRE TO PRIMARY COIL BLACK WIRE TO SECONDARY CSI f COL WIRES CIRCUIT BREAKER TAN AND BL
226. es Test Procedure 3 AC Power and Continuity Test of AC Circuit Continued 6 Ifthe circuitis not complete check the wiring of the AC cord transformer primary coil wires and internal AC circuit breaker Figure 5 16 Page 5 19 7 f 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 5 20 8 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 RECTIFIER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 The rectifier converts the AC voltage from the transformer secondary coil to DC voltage This conversion is necessary since the batteries require DC voltage for charging A failed or improperly wired rectifier could result in little or no battery charging current or a tripped AC circuit breaker 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect all four wires from the rectifier Figure 5 12 Page 5 16 Figure 5 12 Rectifier Test Figure 5 13 Rectifier Test Probes Reversed Pag
227. es not appear to be operating properly or if the batteries appear to be weak contact your Club Car distributor dealer TESTING CHARGER OPERATION 1 With the DC plug disconnected from the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 2 Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle The charger relay should close with an audible click after a 2 to 15 second delay See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 6 2 3 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 6 3 Page 6 4 and that the internal charger wiring is correct Figure 6 9 Page 6 11 TRANSFORMER g TAN TAN BLACK PRIMARY AC CIRCUIT AC CORD BLACK 7 BREAKER Sp foc BLACK G D 100 Ohm RELAY BOARD ASSEMBLY WITH SUPPRESSOR Figure 6 9 PowerDrive 3 Battery Charger Wiring Diagram External Charger DC CORD AND PLUG INSPECTION The charger cord plug and receptacle
228. esentatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent Club Car s continuing commitment to customer support Club Car offers a full line of training and continuing education classes for technicians who want to learn more about our products For more information contact your local dealer or Club Car s Technical Services depart ment for a list of upcoming classes This manual covers all aspects of typical battery charger service unique situations however do sometimes occur when servicing a charger If it appears that a service question is not answered in this manual you may write to us at Club Car LLC P O Box 204658 Augusta Georgia 30917 Attention Technical Services Copyright 2007 2009 2010 Club Car LLC Club Car and PowerDrive are registered trademarks of Club Car LLC This manual effective August 6 2007 2008 2011 Domestic Battery Charger Maintenance and Service Manual Pagei A WARNING e Read Section 1 Safety before attempting any service on a Club Car vehicle or charger Before servicing a Club Car vehicle or charger read complete section s and any referenced information that may be relevant to the service or repair to be performed NOTE This manual represents the most current information at the time of publication Club Car LLC is continually working to further improve our vehicles and other products These improveme
229. esting siente te teer ec 9 15 troubleshooting sees 9 6 PowerDrive 2 charger AC circuit breaker charger see circuit breaker AC cord Installation vis 2 eem 5 29 removal 25 0 n Rete et ee 5 29 testing ERE 5 20 ammeter installation 2 ome rU eS 5 27 removal er 5 26 testing eicere tinere pe detected 5 22 batteries battery condition after a charge cycle 5 9 charging batteries that have low voltage 5 29 state of charge test sssssssssssess 5 20 battery charger installation irte ui 5 4 Operation erre rte a tede 5 6 IGp llS 4 ue e err REM es 5 23 testing eve ee ceste edes 5 7 breaker charger circuit see circuit breaker charge circuit sessssssssssseeeeee 5 3 circuit breaker installation 5 29 removal 5 inc ak tionen 5 28 testing oo ee ete E deed 5 23 cord charger see AC cord or DC cord DC cord inspection etre 5 8 installation 32 neni Bee 5 24 REMOVAL 3 nape eae eneen a rara EN etri ec 5 23 TESTING soe edocs o rect 5 17 5 21 diodes charger see rectifier electrical system charge circuit onere nine 5 3 fuse Ime MI EE 5 20 fuse link installation 22 1 3 1 centes 5 27 remoVali eine eee ERE 5 27 long term storage charge 5 2 onboard computer leStirig eet natu 5 15 2008 2011 Domestic Battery Charger Maintenance and
230. ews 3 Figure 6 24 Page 6 28 2 Connect the white wire from the ammeter to the positive terminal of the rectifier Figure 6 9 Page 6 11 See following NOTE NOTE The positive terminal of the rectifier is marked on the edge of the rectifier case The positive ter minal can also be identified by its orientation and the chamfered corner of the rectifier case 3 Connect the two black transformer secondary coil wires to the AC terminals on the rectifier 4 Connect the brown wire from the charger fuse to the negative rectifier terminal See following CAU TION CAUTION Improper wiring of the rectifier could result in damage to the rectifier and cause the AC circuit breaker to trip 5 Gently press the fuse link 2 into the mounting tab so that the fuse link is visible from the rear of the charger 6 Install the charger cover and check charger for proper operation TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 Transformer Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the black primary coil wire 5 from the charger relay Figure 6 22 Page 6 24 4 Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan pri mary coil wire c1 Disconnect the AC cord white wire 4 from the primary coil tan wire 6 If equipped remove
231. ey are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 DS DS Villager 4 Turf 1 Carryall 1 800 810 and 850 Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figure 3 2 Page 3 3 and Figure 3 3 Page 3 4 3 2 Make sure the two nuts that secure the two 10 gauge black wires to the receptacle fuse assembly are tight Figure 3 11 Page 3 16 CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER SENSE LEAD FUSE Figure 3 11 Receptacle Wire Connections all vehicles except Precedent 3 3 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sense lead fuse to the onboard computer gray wire See following WARNING Page 3 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Test Procedures EJ A WARNING Do not bypass the sense lead fuse 3 4 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistance should be less than 2 ohms 3 5 Precedent Verify that the 10 gauge red wire from the charger receptacle is connected to the pos itive post of battery no 1 Figure 3 4 Page 3 5 Figure 3 5 Page 3 6 and Figure 3 6 Page 3 7 4 Check battery pack voltage 4 1 DS DS Villager 4 800 810 and 850 With a multimeter set to 200 volts DC measure the voltage of the
232. f the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 3 16 Page 3 18 AN Bn i 25 3 Figure 3 16 Battery Voltage Test Style C Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 5 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 3 34 Page 3 18 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Test Procedures EU TEST PROCEDURE 2 ONBOARD COMPUTER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 1 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to This will ensure that AC power is present 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Insertthe DC cord from the second charger into the receptacle of the vehicle that is not charging properly 4 Ifthe second charger fails in the same manner as the first charger then the
233. fore attempting any repair Figure 9 3 Page 9 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 Onboard Charger Removal 1 Disconnect the batteries and discharge the controller See Disconnecting The Batteries on page 1 3 2 Disconnect the charger DC cord at the three pin connector 1 Figure 9 22 Page 9 32 3 For Carryall 2 252 and 6 Turf 2 252 XRT 900 and Transporter 4 and 6 vehicles Carefully remove the heatshrink tubing from the AC cord connection and disconnect the short AC cord from the retractable cord reel Figure 9 13 Page 9 18 4 Remove hardware securing charger to chassis 4 1 Villager 6 and 8 Remove four bolts 2 flat washers 3 lock washers 4 and nuts 5 from charger mounting plates 4 2 Carryall 2 252 Turf 2 252 and XRT 900 Remove two bolts 2 from topside of charger mounting plate 4 3 Carryall 6 and Transporter 4 and 6 Remove two nuts 5 from underside of charger mounting plate 5 Lift charger assembly from vehicle Onboard Charger Installation 1 Installation is reverse of removal 2 Install and tighten hardware securing charger to chassis 2 1 Villager 6 and 8 Tighten four bolts 2 and nuts 5 to 108 in Ib 12 N m 2 2 Carryall 2 252 Turf 2 252 and XRT 900 Tighten two bolts 2 to 108 in Ib 12 N m 2 3 Carryall 6 and Transporter 4 and 6 Tighten tw
234. g could result in charger malfunction property damage or severe personal injury Install the charger cover and check charger for proper operation 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 25 Charger Repairs E EN IQ PLUS CHARGER EXTERNAL Charger Repairs AMMETER See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 Ammeter Removal 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the black wire from the DC cord 5 and the buss bar 3 from the ammeter Figure 8 18 Page 8 26 Remove the two nuts 2 that secure the ammeter to the charger face Remove the ammeter from the face of the charger Ammeter Installation Place the ammeter in position in the charger face Figure 8 18 Page 8 26 Install nuts 2 and tighten until ammeter is firmly secured Connect the black wire of the DC cord 5 to the left as viewed from inside the charger post of the amme ter Connect the buss bar 3 from the fuse link to the right post of the ammeter Place flat washers on both sides of the buss bar Thread nuts 4 onto both posts of ammeter until just past finger tight While holding the inside nut tighten the outside nut 4 1 4 turn See following CAUTION CAUTION 6 Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged
235. g off season or long term storage The onboard computer will auto matically activate the charger every 15 days To return the vehicle to service unplug the charger DC cord wait 15 seconds for the computer to reset and plug the charger back in See following WARN ING and CAUTION This will ensure the batteries are at their optimum charge prior to returning the vehicle to service A WARNING The charger plug must be pulled slowly from the receptacle Figure 7 7 Page 7 9 Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode Figure 7 8 Page 7 9 CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and ensure the charger is operating correctly during storage BATTERY WARNING LIGHT IQ System and Excel System vehicles feature a dash mounted battery warning light above the steering col umn that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light w
236. ge 3 19 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 3 24 Failed transformer Test Procedure 6 Transformer on page 3 22 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 19 Charger failure See Testing Charger Operation on page 3 11 16 hour time out See Battery Warning Light on page 3 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Battery warning light illuminates for ten seconds at four second intervals with DC charger cord unplugged 25 seconds at 10 second intervals for Precedent vehicles Batteries are getting close to full discharge capacity Recharge batteries golf round may be completed first Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 19 Battery or batte
237. ge to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot motor or resistors Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Prior to servicing the vehicle or leaving the vehicle unattended turn the key switch OFF remove the key and place the Forward Reverse handle or switch in the NEUTRAL position Chock the wheels when servicing the vehicle
238. gure 7 22 Page 7 25 4 Place a piece of heatshrink tubing over the AC cord white wire 5 Connect the AC cord white wire 4 to the tan primary coil wire Figure 7 22 Page 7 25 6 Slide the heatshrink tubing 7 over the connection and apply heat to the heatshrink to insulate the con nection between the AC cord white wire and the tan primary coil wire See following WARNING A WARNING T Make sure the electrical connections are properly insulated Failure to properly insulate electrical connections in the charger could result in a short circuit If equipped replace wire tie s securing transformer wires See following WARNING A WARNING 8 Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Install the charger cover and check charger for proper operation Page 7 30 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Charger Repairs AMMETER See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 Ammeter Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord red wire 1 and the white wires 2 and 3 from the ammeter 4 Figure 7 24 Page 7 31 4 Press the locking tabs on each side of the ammeter and remove the ammeter by gently push
239. gure 8 6 Page 8 12 There should be no continuity POSITIVE PIN POSITIVE PIN m PULL HERE emm PULLER us NEGATIVE PIN NEGATIVE PIN Figure 8 12 DC Plug Test Figure 8 13 DC Plug Test Probes Reversed 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 4 To apply AC power directly to the transformer primary coil the relay must be bypassed Disconnect transformer secondary coil wires 1 and 5 from the heatsink Figure 8 14 Page 8 19 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 F
240. harger Long Term Storage Charge This charger is designed to be left connected to AC power during off season or long term storage Be sure to check the charger monthly to ensure the charger is operating correctly during storage The charger will enter maintenance mode if supported by the charge algorithm or automatically activate if battery voltage drops 2 1 Volts per cell 24 cells is 50 4 Volts or 30 days have elapsed To return the vehicle to service disconnect the AC cord from the wall outlet wait 15 seconds and then plug the AC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before put ting it into service UL AND CSA LISTING When operated on a 120 volt 60 Hz electrical system this battery charger has been listed by Underwriters Laboratories and by the Canadian Underwriters thereby meeting the criteria of the Canadian Standards Association CE COMPLIANCE This battery charger is compliant with the EU EMC Directive 2004 108 EC IP INGRESS PROTECTION RATING The enclosure of the charger has been tested successfully to EN60529 meeting IP66 The AC supply inlet is rated to IP20 which is suitable for indoor use only Keep all AC connections clean and dry Page 10 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD General Information HOW TO IDENTIFY CHARGE ALGORITHM NUMBER The algorithm numbers offered can be found in Battery Cha
241. harger cover 3 Disconnect the two black wires attached to the AC circuit breaker Figure 4 25 Page 4 29 4 With a pair of pliers squeeze in the retaining tabs on the sides of the AC circuit breaker and remove the circuit breaker through the mounting hole in the face of the charger AC Circuit Breaker Installation Install in reverse order of removal CHARGER AC CORD AND RETRACTABLE CORD REEL See General Warning Section 1 Page 1 1 Short AC Cord Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 2 Remove the charger cover 3 Disconnect the AC cord black wire from the AC circuit breaker Figure 4 25 Page 4 29 4 Disconnect the AC cord white wire from the control board 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 29 POWERDRIVE CHARGER ONBOARD Charger Repairs 5 Disconnect the AC cord green wire from the charger base Figure 4 25 Page 4 29 6 Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger Short AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Figure 4 25 Page 4 29 2 Connect the black wire to the AC circuit breaker the white wire to the control board and the green wire to the charger base Figure 4 4 Page 4
242. harger into the receptacle of the vehicle that is not charging properly 4 Ifthe second charger fails in the same manner as the first charger then the vehicle charging circuit is not functioning properly See Troubleshooting on page 6 12 5 Connectthe first charger into another vehicle that is known to be functioning properly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC wall outlet voltage should be between 105 and 128 volts If proper voltage is not present have building wiring checked by a licensed electrical contractor 5 Check continuity of the AC circuit 5 1 Remove the charger cover 5 2 Bypass the relay See step 4 of Charging a Battery Pack that has Low Voltage on page 6 34 See following DANGER A 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 3 With relay bypassed there should be continui
243. harger recepta cle If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check wire continuity and connections between the charger receptacle onboard computer and batteries Page 3 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL The Charge Circuit CHARGER FRONT RECEPTACLE OF VEHICLE ae gt ANHO 8Lit z 3 D 4 BATTERY BANK TO SOLENOID MOVIE OL SINGLE POSITION CONNECTOR ONBOARD COMPUTER SOLID STATE SPEED CONTROLLER Figure 3 6 Charge Circuit and Style C Battery Configuration 6 x 8 Volt Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 7 ES POWERDRIVE CHARGER EXTERNAL Charger Installation and Operation CHARGER INSTALLATION AND OPERATION See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosi
244. he DC cord have it replaced immediately Page 5 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Checking Battery Condition After a charge Cycle Eu CHECKING BATTERY CONDITION AFTER A CHARGE CYCLE See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ System PowerDrive and Precedent vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illuminate intermittently See following NOTE If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual appropriate for your battery charger If you do not have this publication contact your Club Car representative If the specified test procedures identify no problems plug the DC cord into the vehicle and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle charger receptacle
245. hicles will damage the batteries Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use External battery chargers Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Onboard battery chargers Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal Section 4 Page 4 33 If wires are removed or replaced make sure wiring and wire harness are properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes A CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and ensure the charger is operating correctly during storage DISABLING THE VEHICLE mes QOO
246. ic Code and all local codes and ordinances The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 meters Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Mount charger by setting it on a shelf wall mount with keyhole or hang securely from ceiling by the handle Do not hang charger upside down Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Be sure the fuse link is clean and tight not applicable to Precedent vehicles Be sure all wire connections at the receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 7 7 Page 7 9 Do not pull on the DC cord Figure 7 8 Page 7 9 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle WARNING CONTINUED ON NEXT PAGE 2008 2011 Domestic Ba
247. icle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the vehicle has been driven even if only a few feet the onboard computer will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle continues If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 7 9 Page 7 11 and Figure 7 10 Page 7 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Page 7 12 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Troubleshooting Use the following Troubleshooting Guide for troubleshooting PowerDrive 3 external battery chargers model numbers 26580 11 26580 18 and 26580 19 The Troubleshooting Guide encompasses the entire battery
248. iddle pin The tester should indicate continuity If tester does not indicate continuity replace DC cord Transformer The PowerDrive 2 battery charger transformer has two sets of coils a primary coil and a secondary coil Figure 5 16 Page 5 19 Primary Coil 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 21 E POWERDRIVE 2 CHARGER EXTERNAL Test Procedures 3 Carefully cut the heatshrink that insulates the AC cord white wire 4 where it connects to the tan primary coil wire Figure 5 17 Page 5 20 4 Disconnect terminals from transformer tan and black primary coil transformer wires 4 and 6 Figure 5 16 Page 5 19 5 Place the continuity tester probes on the disconnected primary coil wires The tester should indicate con tinuity If tester does not indicate continuity replace the transformer 6 Ifthe correct readings were obtained install the AC cord and connect the transformer primary coil wires See AC Cord Installation on page 5 29 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 black secondary coil wire 1 from the rectifier Figure 5 16 Page 5 19 4 Remove the other transformer black secondary coil wire 5 from the rectifier 5 Place the continuity tester probes
249. ies charged in unheated areas should be placed on charge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CC P N 101831801 See Communication Display Module in Section 11 of the appropriate mainte nance and service manual 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 5 POWERDRIVE CHARGER ONBOARD Checking Battery Condition Testing Charger Operation 1 Connect the AC power supply cord to a 120 volt AC 60 hertz single phase outlet The charger relay should not close immediately but should close with an audible click after a delay of 2 to 15 seconds See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warni
250. ight will illuminate and remain illuminated for 10 seconds 25 seconds for Precedent vehicles if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the opera tor that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals 25 seconds at 10 second intervals for Precedent vehicles if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals 25 seconds at 10 second intervals for Precedent vehicles during a charge cycle with the DC plug still connected if AC power to the charger is interrupted The light will go out when AC power is restored Page 5 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL The Charge Circuit REN THE CHARGE CIRCUIT The vehicle charge circuit consists of the following charger receptacle receptacle fuse link onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black w
251. igure 6 7 Page 6 9 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 6 8 Page 6 9 GENERAL INFORMATION This section includes information pertaining to service of the PowerDrive 3 battery charger model numbers 26560 11 26560 18 and 26560 19 Figure 6 1 Page 6 1 Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor Figure 6 1 PowerDrive 3 Battery Charger The PowerDrive 3 battery charger is automatic and has no external controls When the charger is connected there is a 2 to 15 second delay before charging begins NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer having recorded the amount of energy consumed as the vehicle was used directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies 2008 2011 Domestic Battery Charger Maint
252. igure 8 14 Page 8 19 See following DANGER A DANGER 5 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 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 IQ PLUS CHARGER EXTERNAL Test Procedures EN 2 DIODES WITH DC CORD HEATSINK Lm e AC CIRCUIT BREAKER SECONDARY COIL AMMETER PRIMARY COIL TRANSFORMER Bc Figure 8 14 Transformer Test Wiring Diagram 6 Ifthe 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 5 9 Connectthe AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced Figure 8 14 Page 8 19 10 Ifthe voltage reading is normal 86 volts AC or higher the transformer is operational
253. igure 8 4 Page 8 7 GENERAL INFORMATION This section includes information pertaining to service of the IQ Plus battery charger model numbers 25730 11 25730 18 and 25730 19 Do not attempt to service a battery charger that has not been properly identi fied If a charger cannot be properly identified contact your local Club Car dealer or distributor The IQ Plus battery charger is automatic and has no external controls Figure 8 1 Page 8 1 When the charger is connected there is a 2 to 15 second delay before charging begins See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer having recorded the amount of energy consumed as the vehicle was used directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies Figure 8 1 IQ Plus External Charger Model 25730 11 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 1 EN IQ PLUS CHARGER EXTERNAL General Information IQ PLUS EXTERNAL CHARGER FEATURES Charge Interl
254. ill not illuminate if the charge is 9096 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger DC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the fleet operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals during a charge cycle with the DC plug still connected if AC power to the charger is interrupted The light will go out when AC power is restored The battery warning light will flash quickly after inserting the DC plug indicating the charger s voltage suppressor has failed closed Page 7 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 The Charge Circuit THE CHARGE CIRCUIT DS 800 810 AND 850 VEHICLES 4 X 12 VOLT The vehicle
255. imately 110 to 128 volts AC 5 If reading is incorrect replace control board 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 11 9 IQ PLUS CHARGER ONBOARD Test Procedures BLACK WIRE TO RELAY BLACK WIRE TO AC CIRCUIT BREAKER TAN WIRE TO TRANSFORMER BLUE WIRE TO RELAY SS PRIMARY COIL RED WIRE TO RELAY ay 1 WHITE WIRE TO AC CORD RED WIRE TO HEATSINK BLUE WIRE TO DC CORD Figure 9 7 Control Board TEST PROCEDURE 3 AC POWER AND CONTINUITY CHECK OF AC CIRCUIT See General Warning Section 1 Page 1 1 1 Disconnect the AC power supply cord from the wall outlet 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC Check the AC line fuse or circuit breaker in the storage facility wall outlet voltage should be between 105 and 128 volts If proper voltage is not present have building wiring checked by a licensed electrical contractor Check continuity of the AC circuit 5 1 Remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 5 2 Remove the charger cover 5 3 Bypass the relay 5 3 1 To bypass the relay remove the black wire 3 from the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 9 11 Page 9 16
256. imeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 7 14 Page 7 18 or Figure 7 15 Page 7 18 200 DCV SETTING Figure 7 14 Battery Voltage Test Precedent Style A Figure 7 15 Battery Voltage Test Precedent Style B Battery Configuration Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 RED probe to battery no 1 1 RED probe to battery no 1 2 BLACK probe to battery no 4 2 BLACK probe to battery no 4 4 4 Style C 6 x 8 Volt Precedent only With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 7 16 Page 7 18 Figure 7 16 Battery Voltage Test Precedent Style C Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 5 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 7 34 Page 7 18 2008 2011 Domestic Battery Charger Maintenance and Service Man
257. imeter should indicate approximately 922 mV 4 If multimeter readings are incorrect check the battery charger wiring Figure 6 9 Page 6 11 5 If the multimeter indicates an overload no continuity in both directions and the charger fuse is not blown individually check all connections and the continuity of the DC cord and ammeter See Test Pro cedure 8 Continuity on page 6 23 Also check the rectifier See Test Procedure 4 Rectifier on page 6 20 If the multimeter indicates a voltage reading in both directions a short circuit exists in the charger DC cir cuit usually caused by a failed rectifier See Test Procedure 4 Rectifier on page 6 20 If the rectifier has not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 6 23 POSITIVE PIN DIODE SETTING Figure 6 21 DC Plug Test Probes Reversed TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 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
258. inate and remain illuminated for 10 seconds 25 seconds for Precedent vehicles if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the opera tor that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals 25 seconds at 10 second intervals for Precedent vehicles if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer THE CHARGE CIRCUIT For vehicles with onboard chargers the charge circuit consists of the following components onboard charger onboard computer batteries DS Villager 4 The black wire from the charger is connected to the fuse link along with the short black receptacle wire on the charger receptacle Figure 4 2 Page 4 3 One 10 gauge black wire from the onboard computer con nects to other side of the charger receptacle fuse link The other 10 gauge black wire from the onboard com puter connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The red wire of the charger is connected to the positive post of battery no 1 The blue
259. indicate continuity then the fuse has failed and must be replaced AC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 7 22 Page 7 25 4 Disconnect the black wire 1 of AC cord from charger AC circuit breaker 3 5 Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan pri mary coil wire 6 Disconnect the AC cord white wire 4 from the primary coil tan wire 7 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug 6 The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced 8 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug 6 Figure 7 22 Page 7 25 The tester should indi cate continuity on only the round pin If any other reading is obtained the AC cord and plug must be replaced 9 Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug 6 The tester should indicate continuity on on
260. ined install the AC cord and connect the transformer primary coil wires See AC Cord Installation on page 7 33 Secondary Coil 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove the orange and purple transformer secondary coil wires 1 and 2 from each diode Figure 7 9 Page 7 11 Place the continuity tester probes on the disconnected secondary coil wires The tester should indicate continuity between the orange and purple wires If tester does not indicate continuity replace the trans former Voltage Suppressor Failed Closed The voltage suppressor which is incorporated into the relay board assembly protects the onboard computer by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehicle 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Using a multimeter set to the diode test function place the black probe of the multimeter on the 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 1 5 3 volts If a reading of lt 5 volt then the voltage suppressor has shorted and the relay should be replaced If the meter indicates an overload condition then the voltage
261. ing battery cables 2 Remove negative battery cable 2 Remove negative battery cable 3 Remove positive battery cable 3 Remove positive battery cable Connect battery cables in reverse order Connect battery cables in reverse order Figure 1 3 Precedent Battery Configuration Style C Figure 1 4 DS DS Villager 4 800 810 850 and Carry 6 x 8 Volt Batteries all 232 IQ System 4x12 volt Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables connecting battery cables 2 Remove negative battery cable 2 Remove negative battery cable 3 Remove positive battery cable 3 Remove positive battery cable Connect battery cables in reverse order Connect battery cables in reverse order Page 1 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual SAFETY General Warning Figure 1 5 Turf1 and Carryall 1 Battery Configuration Figure 1 6 Turf 2 and 252 Carryall 2 and 252 XRT 900 IQ Plus and Carryall 6 IQ Plus Style B Battery Config uration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables connecting battery cables 2 Remove negative battery cable 2 Remove negative battery cable 3 Remove
262. ing the ammeter through the front of the charger case Figure 7 24 Ammeter Ammeter Installation 1 Place the ammeter 4 in position in the charger face and ensure that the locking tabs are secure Figure 7 24 Page 7 31 2 Connect the DC cord red wire 1 and the white wires 2 and 3 to the ammeter terminals 3 Install the charger cover 4 Plug the charger into the vehicle and check ammeter for proper operation 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 31 POWERDRIVE 3 MODEL 26580 Charger Repairs FUSE LINK See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 Fuse Link Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Gently press the fuse toward the transformer to remove the fuse from the mounting tab 4 Remove the two nuts securing the two wires to the fuse terminals and remove the fuse Fuse Link Installation 1 Connect the short brown wire from the top diode heatsink to one of the fuse terminal posts and install the nut Tighten nut to 23 in Ib 2 6 N m 2 Connect the DC cord black wire to the other fuse terminal post and install the nut Tighten nut to 23 in Ib 2 6 N m 3 Gently press the fuse assembly into the mounting tab so that the fuse link is visible from the rear of the charger 4 Install the charger cover RELAY BOARD ASSEMBLY See General Warning Section 1 Page
263. ining tabs on the sides of the AC circuit breaker and remove the circuit breaker through the mounting hole in the face of the charger AC Circuit Breaker Installation 1 Install in reverse order of removal CHARGER AC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 AC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the AC cord black wire from the AC circuit breaker Figure 3 27 Page 3 33 Disconnect the AC cord white wire from the primary coil tan wire Disconnect the AC cord green wire from the charger base Figure 3 27 Page 3 33 2 aR WN Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger Page 3 32 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL TAN WIRE TO PRIMARY COIL GREEN GROUND WIRE BLACK WIRE TO RELAY BLACK WIRE TO CIRCUIT BREAKER BLUE WIRE TO DC CORD TAN WIRE TO PRIMARY COIL VOLTAGE SUPPRESSOR RED WIRE TO HEATSINK Charger Repairs EJ WHITE WIRE FROM AC CORD STRAIN RELIEF BUSHING AC CIRCUIT BREAKER CHARGER RELAY Figure 3 27 Charger Relay AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Figure 3 27 Page 3 33 2 Connect the black wire to the AC circui
264. inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 9 2 2 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 9 2 Page 9 3 and that the internal charger wiring is correct Figure 9 3 Page 9 6 DC CORD DIODES WITH HEATSINK TRANSFORMER AC CIRCUIT BREAKER BLACK GROUND Figure 9 3 IQ Plus Onboard Battery Charger Wiring Diagram TROUBLESHOOTING See General Warning Section 1 Page 1 1 A 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 Page 9 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual Troubleshooting ERI Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 9 3 Page 9 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 IQ PLUS CHARGER ONBOARD A WARNING Use the following Troubleshooting Guide for troubleshooting the IQ Plus onboard battery charger model numbers 25260 11 and 25260 50 The Troubleshooting Guide encompasses the entire
265. internally and must be replaced Figure 5 16 Page 5 19 10 Ifthe voltage reading is normal 43 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 5 17 11 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 BLACK AC CIRCUIT DISCONNECTED fi PRIMARY SECONDARY VOLTAGE BREAKER SUPPRESSOR eel GOIL TAN BLACK D I AC INPUT PLUG I DISCONNECTED FROM RELAY i GROUND AND CONNECTED TO BREAKER AC RECTIFIER 5 TAN BLACK Lt WHITE Figure 5 16 Transformer Test Wiring Diagram 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 19 ES POWERDRIVE 2 CHARGER EXTERNAL Test Procedures TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and then reconnect it The ammeter should jump to a reading between 12 and 14 amps and then taper to below 5 amps within 15 minutes
266. inuity Test Page 8 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Test Procedures EN DC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 8 16 Page 8 23 Disconnect the red wire of the DC cord from the heatsink Disconnect the blue wire from the red wire assembly that connects to the charger relay Place the clip of the continuity tester on the red wire of the DC cord N Oa s 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
267. inuity test probes on contact terminals of relay With batteries connected insert DC plug into receptacle The tester should indicate continuity If tester does not indicate continuity relay must be replaced Ammeter 1 2 3 4 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the white wire from the left ammeter terminal as viewed from inside the charger Place the continuity tester clip on one of the ammeter posts Page 5 22 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Charger Repairs E 5 Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the wires from the AC circuit breaker 4 Place the continuity test probe on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuity replace the AC circuit breaker CHARGER REPAIRS See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 5 6 Page 5 8 Prior to servicing the charger disconn
268. ional WARNING on page 8 1 The voltage suppressor which is incorporated into a wire assembly in the charger protects the onboard com puter by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehicle See also Test Procedure 8 Conti nuity on page 8 20 Voltage Suppressor Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove nut attaching voltage suppressor 18 gauge red wire to heatsink Figure 8 19 Page 8 29 4 Disconnect the blue and red wires from the relay 5 Disconnect the DC cord blue wire at the quick disconnect terminal 6 Remove the voltage suppressor and wire assembly from the charger Voltage Suppressor Installation 1 Install in reverse order of removal Tighten nut attaching voltage suppressor 18 gauge red wire to heat sink to 18 in Ib 2 0 N m See following NOTE NOTE The charger relay blade connector is located off center within the relay housing When connecting voltage suppressor slip on connector to relay blade connector make sure slip on connector is positioned so that flat side of connector is closest to relay housing Figure 8 19 Page 8 29 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 27 EN IQ PLUS CHARGER EXTERNAL Charger Repairs CHARGER RELAY See General Warning Section 1 P
269. ircuit breaker may trip off If both diodes have failed open or closed the entire diode heatsink assembly 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 7 11 Page 7 16 through Figure 7 16 Page 7 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 left side of the ammeter when viewed from inside the charger the DC cord blue wire should be connected to the relay coil and the DC cord black wire should be connected to the fuse link Figure 7 9 Page 7 11 If a reverse polarity connection is made between the charger and the batteries the fuse link 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 the fuse link to blow Be sure fuse connections are tightened to 23 in Ib 2 6 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 7 1 1 Disconnect the AC cord from the wall outlet and the DC cord from the vehicle charger receptacle 2 Using
270. ire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the positive post of battery no 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse on all vehicles except Precedent vehicles and the 18 gauge gray wire from the onboard computer On all vehicles except Precedent vehicles also check connections of the fuse link located on the charger receptacle Figure 5 2 Page 5 3 or Figure 5 3 Page 5 4 ONBOARD SOLID STATE COMPUTER i SPEED CONTROLLER III be i ii MI E TERMINAL RED TO 7 6 BLACK POSITIVE M CHARGER TERMINAL T AEN RECEPTACLE 10 BLACK al gt 18 GRAY 18 GRAY N Er 10 RED To Solenoid SENSE LEAD FUSE BLACK TO NEGATIVE TERMINAL Figure 5 2 Charge Circuit and Battery Configuration DS Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 3 Ig POWERDRIVE 2 CHARGER EXTERNAL Charger Installation and Operation KS SHARO Ie SOLENOID RECEPTACLE OF VEHICLE PAY D
271. ith your vehicle may be a different model Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly iden tified contact your local Club Car dealer or distributor For battery chargers with model numbers listed above that are installed in vehicles other than DS and Prece dent vehicles contact your local Club Car dealer or distributor The PowerDrive battery charger is automatic and has no external controls Figure 4 1 Page 4 1 When the AC cord is plugged in there is a 2 to 15 second delay before charging begins The onboard computer OBC records the amount of energy consumed as the vehicle is used then directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger shuts off automatically preventing the possibility of either undercharging or overcharging See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge Figure 4 1 Onboard PowerDrive Battery Charger 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 1 POWERDRIVE CHARGER ONBOARD The Charge Circuit POWERDRIVE ONBOARD CHARGER FEATURES Charge Interlock When the AC power cord is inserted into a wall receptacle the onboard computer locks out the v
272. jp Harness Gray Connector Solenoid AC Cord ONBOARD CHARGER BATTERIES 6 GA BLACK Figure 10 3 Charge Circuit ONBOARD CHARGER OPERATION A DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion Risk of electric shock Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances A grounded outlet is required to reduce risk of electric shock do not use ground adapters or modify plug Do not touch uninsulated portion of output connector or uninsulated battery terminals Disconnect the AC supply before making or breaking the connections to the battery Do not open or disassemble charger Do not operate this charger if the AC supply cord is damaged o
273. ker 3 Figure 6 22 Page 6 24 Place a piece of heatshrink tubing 7 over the AC cord white wire 4 Connect the AC cord white wire 4 to the tan primary coil wire Figure 6 22 Page 6 24 Qu e eU IN Slide the heatshrink tubing 7 over the connection and apply heat to the heatshrink to insulate the con nection between the AC cord white wire 4 and the tan primary coil wire See following WARNING A WARNING Make sure the electrical connections are properly insulated Failure to properly insulate electrical connections in the charger could result in a short circuit 6 Connect the green wire 2 to the charger base Tighten the screw and nut on the green ground wire terminal to 18 in Ib 2 0 N m 7 Position the strain relief bushing on the AC cord 8 Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 9 Install the charger cover 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 33 ES POWERDRIVE 3 MODEL 26560 Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger See following WARNING A WARNING Knowledge of battery charger wiring and component terminology is required before at
274. kets or other materials to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes Note Appearance of receptacle Note Appearance of may vary depending on vehicle receptacle may vary depending on vehicle Figure 5 4 Charger Receptacle Figure 5 5 Incorrect DC Plug Removal 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 5 E POWERDRIVE 2 CHARGER EXTERNAL Charger Installation and Operation AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions With charger DC output cord disconnected connect the power supply cord to an AC supply See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug It is for use on a nominal 120 volt 60 hertz circuit The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local code
275. lace Bat Es 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 13 HIGH FREQUENCY CHARGER ONBOARD Interpreting the Results of the Hydrometer Test 6 Volt Batteries The approximate state of charge can be determined from the following table SPECIFIC GRAVITY Eee EMRERAIURE STATE OF CHARGE CORRECTED 1 250 1 280 100 1 220 1 240 75 1 190 1 210 50 1 160 1 180 25 Test Procedures If the difference between the cells is 0 020 or more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery with the low cell should be replaced CORRECTED SPECIFIC GRAVITY VEHICLE BATTERY ELECTROLYTE CORRECTION REQUIRED NO NO TEMPERATURE FACTOR CELL 1 CELL 2 CELL 3 ACTION 1 275 0 024 1 280 0 024 1 280 0 024 Sound Battery 12 1 20 F 6 6 C 0 024 21 251 1 256 1 256 Fully Charged Discharged 35 6 90 F 32 2 C 0 004 112S nO O0 ese 1 180 t 0 004 Battery 1 Recharge 54 3 50 F 10 C 0 012 1 200 0 0121 2005 0O12 1 200012 Badio Cel Weak no 3 1 250 0 1 255 0 1 230 0 69 5 80 F 26 7 C 0 000 L Cell Catch up 24 250 24255 21 230 ene Discharged 1 200 0 008 1 180 0 008 1 170 0 008 Battery 38 2 100 F 37 8 C 0 008 1 208 1 188 1 178 Recharge and Rech
276. le charging circuit is not functioning properly See Troubleshooting on page 5 9 5 Connectthe first charger into another vehicle that is known to be functioning properly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC wall outlet voltage should be between 105 and 128 volts If proper voltage is not present have building wiring checked by a licensed electrical contractor 5 Check continuity of the AC circuit 5 1 Remove the charger cover 5 2 Bypass the relay 5 2 1 To bypass the relay remove the black wire 3 from the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 5 16 Page 5 19 5 3 With relay bypassed there should be continuity across the AC cord blades Figure 5 11 Page 5 15 Figure 5 11 AC Cord Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 15 ES POWERDRIVE 2 CHARGER EXTERNAL Test Procedur
277. link blows Diode failed Test Procedure 4A Single Diode Failure on page 3 20 Loose internal fuse connection Tighten connection Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B Both Diodes Failed on page 3 21 Troubleshooting Guide continued on next page 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 13 POWERDRIVE CHARGER EXTERNAL Troubleshooting POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Charger output is low One diode failed Test Procedure 4A Single Diode Failure on page 3 20 Transformer coil short circuit failure Test Procedure 6 Transformer on page 3 22 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 19 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 19 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 3 23 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Onboard Computer on pa
278. ll flash each color once starting with red then green and amber If test is suc cessful charging will start and the green light will flash The charger monitors battery voltage charge current and charge time to determine when the batteries are properly charged The charger will shut off by itself and the green light will stop flashing and remain on The vehicle s control circuit lockout remains activated until the charger AC plug is disconnected from the AC receptacle MAINTENANCE Read DANGER WARNING and CAUTIONS beginning on page 10 4 To ensure trouble free performance it is very important to follow an established preventive maintenance pro gram Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Any charger not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic ser vice A WARNING e f any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the charger Do not
279. ll 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 4 2 Page 4 3 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 control board and the DC cord black wire should be connected to the left side of the ammeter when viewed from inside the charger Figure 4 4 Page 4 6 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 Make sure the charger is wired to the vehicle correctly the DC cord red wire should be connected to the same large post as the 6 gauge red wire connected to the positive post of battery no 1 The DC cord blue wire should be connected to the sense lead fuse The DC cord black wire should be connected to the terminal block located on the vehicle component mounting plate Figure 4 2 Page 4 3 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 4 Onrare occasions
280. ltage or when the vehicle is being charged indicates a charg ing problem The battery warning light is controlled by the onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger DC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals during a charge cycle with the DC plug still connected
281. lug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 7 7 Page 7 9 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diag nostic program ammeter will drop to zero See following NOTE NOTE Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be rech
282. ly one flat blade If any other reading is obtained the AC cord and plug must be replaced 10 Ifthe correct readings were obtained install the AC cord See AC Cord Installation on page 7 33 Page 7 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Test Procedures Figure 7 22 AC Cord and Plug Continuity Test DC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the fuse Figure 7 23 Page 7 28 4 Disconnect the red wire of the DC cord from the ammeter 5 Disconnect the blue wire from 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 indicates 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 indicates continuity the DC cord must be replaced 10 Move the continuity test probe to the black wire of the DC cord 11 Pl
283. m overheating Do not allow clothing blankets or other materials to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes AC Power Connection The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions Page 4 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Charger Operation Connect the power supply cord to an AC supply See Section 2 Charger Identification and Specifica tions To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances Place the charger AC cord so it will not be stepped on tripped over or otherwise subject to damage or stress The use of an extension cord with the onboard charger should be avoided Do not place items in the compartment where the battery charger i
284. maged power cords or wires replaced immediately Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes Ensure battery connections are clean and properly tightened Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 5 HIGH FREQUENCY CHARGER ONBOARD CHARGER DISPLAYS 10 LED display on charger Onboard Charger Operation Indication LED Color ed Self Test Solid Displays approximate scale of current output during bulk phase HI Ammeter RUE Amber An High internal charger temperature Output LU Flashing reduced Also displays algorithm 1 6 for 11 ll seconds if no battery is connected ll Solid Bulk charge phase complete 80 charged In 80 e Absorption phase Charge Amber EN Flashina With no battery connected indicates algorithm Seng selected by number of flashes 100 Solid ane complete Charger in
285. mer wires from the fuse Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in Ib 3 2 N m Figure 9 3 Page 9 6 Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect one secondary coil transformer wire black to one terminal of the fuse assembly Tighten nut to 22 in Ib 2 5 N m Connect the other secondary coil transformer wire black to the remaining terminal of the fuse assembly Tighten nut to 22 in Ib 2 5 N m 6 Connect the black primary coil transformer wire to the charger relay 7 Connect the other primary coil transformer wire to the control board 8 Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING 10 Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 9 31 Check charger for proper operation AMMETER See General Warni
286. minal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 5 Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 6 Connect the tan primary coil transformer wire to the charger relay 7 Connect the other tan primary coil transformer wire to the white wire from the AC cord 8 Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING 9 Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Install the charger cover and check charger for proper operation 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 29 E POWERDRIVE CHARGER EXTERNAL Charger Repairs AMMETER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Ammeter Removal 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the black wire from the DC cord 5 and the buss bar 3 from the ammeter Figure 3 26 Page 3 30 Remove the two nuts 2 that secure the ammeter to the charger face Remove the ammeter from the face of the charger Ammeter Installation Place the ammeter in position in the charger face Figure 3 26 Page 3 30 Install nuts 2 and tighten until ammeter is firml
287. move the battery charger from the vehicle See Onboard Charger Removal on page 4 33 DC CORD DC Cord Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 2 Remove the charger cover e Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 4 23 Page 4 24 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink Remove the wire tie that secures the DC cord wire to the secondary coil wire tan Remove the wire tie on the DC cord near the strain relief bushing Disconnect the DC cord blue wire from the control board Figure 4 22 Page 4 24 o oo x Using pliers squeeze the strain relief bushing and remove the DC cord Figure 4 22 Page 4 24 DC CORD BLUE WIRE TO DC CORD CONTROL BOARD BLACK WIRE RED WIRE KI TO HEATSINK STRAIN RELIEF BUSHING Figure 4 22 DC Cord Figure 4 23 DC Cord Replacement Page 4 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Charger Repairs DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base 2 Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18 in Ib 2 0 N m Figure 4 22 Page 4 24
288. n and note the reading Figure 4 14 Page 4 15 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 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 Ib 2 5 N m Page 4 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Test Procedures 8 Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION f connections are not clean and tight excessive heat will be created and the charger may become damaged DISCONNECTED SECONDARY COIL WIRE Figure 4 13 Diode Test Figure 4 14 Diode Test Probes Reversed Test Procedure 4B Both Diodes Failed See General Warning Section 1 Page 1 1 To check the diodes use Test Procedure 4A Single Diode Failure on page 4 14 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 wi
289. n audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Internal AC breaker Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Transformer primary coil Test Procedure 6 Transformer on page 8 18 Relay Test Procedure 8 Continuity on page 8 20 Failed ammeter Replace ammeter Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 4 Diodes on page 8 16 Both Diodes failed Test Procedure 4B Both Diodes Failed on page 8 17 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 8 15 Failed transformer Test Procedure 6 Transformer on page 8 18 Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 8 20 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 8 16 Loose internal fuse connection Tighten connection Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B
290. n page 3 24 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 3 9 Page 3 11 and Figure 3 10 Page 3 15 There should be no continuity POSITIVE PIN POSITIVE PIN PULL RERE PULL ERE NEGATIVE PIN NEGATIVE PIN Figure 3 20 DC Plug Test Figure 3 21 DC Plug Test Probes Reversed TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 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 3 19 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 4 To apply AC power directly to the transformer primary coil the relay must be bypassed Disconnect transformer secondary coil wires 1 and 5 from the heatsink
291. nal of the heatsink and tighten the nut to 18 in Ib 2 0 N m Figure 8 16 Page 8 23 Attach the blue wire of the new DC cord to the red wire assembly at the charger relay Figure 8 16 Page 8 23 Attach black wire 4 of the new DC cord to ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the inside nut 2 tighten the outside nut 1 1 4 turn Figure 8 17 Page 8 23 See following CAUTION CAUTION 5 6 Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter Using pliers put the strain relief bushing on the cord and insert it into the charger base Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING T Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m HEATSINK See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 Heatsink Removal 1 2 3 4 5 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove both secondary coil transformer wires tan from the heatsink Figure 8 5 Page 8 9 and Figure 8 6 Page 8
292. nboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD SOLID STATE COMPUTER SPEED CONTROLLER lif FUSE LINK ii if m NE 10 BLACK Hn l Jue STETIT TERMINAL RED TO 6 BLACK MES B POSITIVE Sede TERMINAL 10 BLACK f RECEPTACLE To Solenoid BLACK TO NEGATIVE TERMINAL Figure 6 3 Charge Circuit and Battery Configuration 6 x 8 Volt Turf 1 and Carryall 1 Vehicles Page 6 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 The Charge Circuit EN PRECEDENT VEHICLES 4 X 12 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 6 4 Page 6 5 or Figure 6 5 Page 6 6 The 1
293. nd receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 1 With the charger DC cord disconnected from the vehicle charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 6 7 Page 6 9 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected See following WARNING A WARNING Do not rock or bend the DC plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 6 7 Page 6 9 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 At one hour and at two hours into the charge cycle the charger will
294. nect the white wire from the left ammeter terminal as viewed from inside the charger Place the continuity tester clip on one of the ammeter posts OU E 9 Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the wires from the AC circuit breaker Seco Place the continuity test probe on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuity replace the AC circuit breaker 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 27 POWERDRIVE 3 MODEL 26580 Charger Repairs CHARGER REPAIRS See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 7 9 Page 7 11 and Figure 7 10 Page 7 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove the DC cord black wire from the fuse by loosening the nut on the fuse Figur
295. ned technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock Use only an appropriately sized AC power cord See AC Power Connection on page 10 7 Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See removal procedure in the appropriate maintenance and service manual Do not use a battery charger if the cord or plug is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or da
296. nee Battery Warning Light toto rette i E OON te e dba a aat ibd ciae ai ts Tine Charge Gir cuit x 2t coton at ii elin pO in E D E DS DS Villager 4 800 810 and 850 ssssssssssssssssssseeeeee nennen nnns Murkland Carryall 22i de c qc Pc teo i caddie ated be adipe cha ld Precedent 4 x 12 Volt 1 esistere dette ted pei d ace da dade ee ded tan ded ud eee dd ened Precedent 6 x 8 VOIE 25 22 deni teer A sien to tu OD REIR ODR POR DARE ERER USE trrae Rer edd Charger Installation and Operation ssssssesseeee nennen nnne AG Power Connection E Charging Batteries 25 2 5 d e entume t ettet ep n D CO DP cdd Testing Charger Operation soiree nteni ara AEAEE R AARE AAEE AAEE EAS a aA DC Cord and Plug Inspection E A E E aE TE Checking Battery Condition After a Charge Cycle sssssessse een Start Gharge Gycle ctn e exea tete tet bee er ore tu Del ee Pax e eaae Xe dudas Troubleshooting E Test Procedures tee e ARR Ea t Lee Index of Test Procedures uic od LE ice cet te bent a aai c LLLA o aa 2008 2011 Domestic Battery Charger Maintenance and Service Manual 1 3 1 3 1 4 2 1 2 2 3 1 3 2 3 2 3 3 3 3 3 4 3 5 3 6 3 9 Page iii DO GCOrd cioe t tite tme aote tete fett terere emet 3 27 Heatsink au Dee e tee ete He EH be fat RE bud ERR EHE RE badd Rea pode de sade Lacks Qu dE e ELE e edge 3 28 TESDSTOITIIGE ettet a tatem ettet p D a te bte t rds 3 29
297. ng Do not allow clothing blankets or other materials to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes Page 7 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Charger Installation and Operation Note Appearance of receptacle Note Appearance of may vary depending on vehicle receptacle may vary depending on vehicle Figure 7 7 Charger Receptacle Figure 7 8 Incorrect DC Plug Removal AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions With charger DC output cord disconnected connect the power supply cord to an AC supply See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug It is for use on a nominal 120 volt 60 hertz circuit The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electr
298. ng Section 1 Page 1 1 Ammeter Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 Page 9 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Charger Repairs EN 2 Remove the charger cover 3 Disconnect the DC cord black wire 5 and the buss bar 3 from the ammeter Figure 9 18 Page 9 25 4 Remove the two nuts 2 that secure the ammeter to the charger face 5 Remove the ammeter from the face of the charger Figure 9 18 Ammeter Ammeter Installation 1 Place the ammeter in position in the charger face Figure 9 18 Page 9 25 2 Install nuts 2 and tighten until ammeter is firmly secured 3 Connectthe black wire 5 of the DC cord to the left as viewed from inside the charger post of the amme ter 4 Connect the buss bar 3 from the fuse link to the right post of the ammeter Place flat washers on both sides of the buss bar 5 Thread nuts 4 onto both posts of ammeter until just past finger tight While holding the inside nut tighten the outside nut 4 1 4 turn See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 6 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 9 31 7 Check charger for prope
299. ng Set on shelf wall mount with keyhole or hang securely from ceiling Mounting Onboard secured to the vehicle 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 2 7 CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications IQ PLUS ONBOARD CHARGER SPECIFICATIONS IQ Plus Onboard Battery Charger Model number 25260 11 25260 50 CC P N 102837001 103772401 AC input AC voltage 105 128 VAC acceptable range Frequency 60 Hz Power consumption Max AC current amps 13 0 13 0 DC output DC voltage VDC start of charge cycle 48 48 DC current amps 17 17 start of charge cycle DC voltage VDC end of charge cycle 60 60 DC current amps end of charge cycle 47 47 Dimensions Weight Case overall length te e ean Case overall width die MS dive Mm Case overall height E ui ont d 17 ft 5 2 m 17 ft 5 2 m AC cord length retractable retractable 22 0 in 22 0 in DC cord length 55 8 cm 55 8 cm 37 0 Ib 37 0 Ib Weight 16 8 kg 16 8 kg Mounting configuration Mounting Onboard secured to the vehicle Page 2 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications HIGH FREQUENCY CHARGER SPECIFICATIONS High Frequency Battery Charger 912 4852 CC PIN ner SVPP325512
300. ng Light on page 4 2 2 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 4 2 Page 4 3 and that the internal charger wiring is correct Figure 4 4 Page 4 6 DIODES WITH HEATSINK GROUND Figure 4 4 PowerDrive Onboard Battery Charger Wiring Diagram CHECKING BATTERY CONDITION See General Warning Section 1 Page 1 1 It is common practice for technicians to check the condition of a set of batteries after they have charged to ensure they have received a complete charge before the vehicle is used With the PowerDrive battery charger this practice is not necessary The onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart See Troubleshooting on page 4 7 If the specified test procedures identify no prob lems plug the AC cord into a wall outlet and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal battery voltage near the end of a charge cycle should be approximately 59 to 63 volts DC while the charger is still operating Start Charge Cycle 1 Disconnect the AC plug from the wall outlet 2 W
301. ng and repairs are complete properly connect the relay wiring See following WARNING A 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 Figure 4 12 AC Circuit Continuity Test TEST PROCEDURE 4 DIODES Use Test Procedure 4A Single Diode Failure on page 4 14 for single diode failures and testing of individual diodes If both diodes have failed use Test Procedure 4B Both Diodes Failed on page 4 15 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 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 ak wn Disconnect AC cord from the wall outlet Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 Remove the charger cover Disconnect one transformer secondary coil wire from the diode terminal Figure 4 13 Page 4 15 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 4 13 Page 4 15 Reverse test probes and check each diode agai
302. ng will resume in a few moments ammeter returns to previous rate of charge The onboard computer having recorded the amount of energy consumed as the vehicle was used directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies Figure 9 1 Onboard IQ Plus Battery Charger 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 1 EN IQ PLUS CHARGER ONBOARD The Charge Circuit IQ PLUS ONBOARD CHARGER FEATURES Charge Interlock When the AC power cord is inserted into a wall receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge IQ Plus chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service disconnect the AC cord from the wall outlet wait 15 seconds and then plug the AC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before putting it into service BATTERY WARNING LIGH
303. nnen nn 4 29 Charger AC Cord and Retractable Cord Reel sssessseeeeeeeen eene 4 29 Retractable AC Cord Reel csetera etude a andae an pede Pd aduana 4 30 Charging a Battery Pack that has Low Voltage ssseem emm 4 31 Onboard Charger Removal and Installation sse eme 4 33 VS VIAGE A rta a eea EE E A A TOE AOA E AA EEE A E 4 33 Precedent Velicles 2 itt A EE LH a be a e Re eb Pe ERE RR ELE 4 34 Page iv 2008 2011 Domestic Battery Charger Maintenance and Service Manual SECTION 5 POWERDRIVE 2 CHARGER EXTERNAL Generalilnformation 5 5 ette mic tti REC P Dm eae on ade n RENE PowerDrive 2 Battery Charger Features ssssssssssseese enne ener Battery Warming LEight i io ee erect The Charge Circuit pLC Charger Installation and Operation cece cece teeter eee eee ee eee tne eee eetaeee eee taeeeeeeeneeeeeeetneeeeeenea AC Power Connection isis deed cedi eed diae e dai dene dd ied ne die reden Charging Batteries e pi eee at imn teles bet eO UO apo D AE Ue e DOR EE REN Testing Charger Operation seeria reaa iar a a ea Ae a A Ea r eraai DC Cord and Plug Inspection ssinieruiiindi inire nenne aa idi ieda di aire r EA Checking Battery Condition After a charge Cycle sssssssssee eme start Charge Cycle estt ene Qn iet gn p eme ides Troubleshootilig 2 ctc ceteri R ASA tete red der tates
304. not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 3 7 Page 3 9 Do not pull on the DC cord Figure 3 8 Page 3 9 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle WARNING CONTINUED ON NEXT PAGE 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 9 POWERDRIVE CHARGER EXTERNAL Charger Installation and Operation A WARNING Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 1 With the charger DC cord disconnected fr
305. nt in one direction only If a diode conducts current shows continuity in both directions the entire diode heatsink assembly must be replaced If a diode does not conduct cur rent does not show continuity in either direction the entire diode heatsink assembly must be replaced 6 Onrare occasions a single fuse link may blow due to excessive heat This can be caused by a loose fuse link connection Check both fuse connections inside the charger to be sure they are clean and tight The proper tightness for the fuse link terminals is 23 in Ib 2 6 N m 7 Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION If connections are not clean and tight excessive heat will be created and the charger may become damaged Page 7 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Test Procedures DISCONNECTED SECONDARY COIL Figure 7 18 Diode Test Figure 7 19 Diode Test Probes Reversed Test Procedure 4B Both Diodes Failed See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 To check the diodes use Test Procedure 4A Single Diode Failure on page 7 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 c
306. ntinuity on one flat blade only If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 8 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug on the retractable cord reel Figure 4 18 Page 4 20 The tester should indicate continuity on only the round pin If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 9 Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug on the retractable cord reel The tester should indicate continuity on only one flat blade If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 10 Ifthe correct readings are obtained in all of the previous steps the short AC cord and the retractable cord reel are functioning properly If any of the readings are incorrect proceed to the following test procedures to determine which of the two components has failed Short AC Cord without Retractable Cord Reel Check continuity of the short AC cord without the retractable cord reel 1 Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 3 Remove the heatshrink from the AC co
307. nts may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car dealers and will when applicable appear in future editions of this manual Club Car LLC reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold There are no warranties expressed or implied in this manual See the limited warranty found in the vehicle owner s manual or write to Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Attention Warranty Administration Page ii 2008 2011 Domestic Battery Charger Maintenance and Service Manual CONTENTS SECTION 1 SAFETY General Warr eaen X Disabling The Vehicle 1 2 occisa rinii ne EA de nte eeu d SEE t dae v nee dd ede Disconnecting The Batteries eeeesssieeessseseeee eene nnnm nnn tnmen en nnne dine nrn nenne nas Connecting The Batteries eei ene erunt TA eran n ERR XAR Ren ERR R nera d edocet SECTION 2 CHARGER IDENTIFICATION AND SPECIFICATIONS Battery Charger Identification essere ERA tnn einen SpecIfICatiOris e cosi timet uanitenuitinuniteidieu eb odi tsi crt SECTION 3 POWERDRIVE CHARGER EXTERNAL General Information 2 necp meta elite RD genet tee PowerDrive External Charger Features sssssssssssseeeeee eene
308. o 2 cell 3 Squeeze the rubber bulb of the hydrometer and insert into the cell Slowly release the bulb drawing elec trolyte up into the glass tube of the hydrometer 4 When the float rises off the bottom adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube Remove the hydrometer from the cell and release the pres sure from the bulb 5 Hold the hydrometer vertically ensuring that the float is not touching the sides of the barrel Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 10 4 Page 10 12 6 Record the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 through 6 on all cells Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 F 26 7 C The readings obtained as described above must be corrected for temperature For each 10 F 5 6 C above 80 F 26 7 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 26 7 C subtract 0 004 from the reading 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 11 HIGH FREQUENCY CHARGER ONBOARD Test Procedures Figure 10 4 Hydrometer Test View at eye level Interpreting the Results of the Hydrometer Test 12 Volt Batteries The approximate state of charge can be determined from the following table SPECIFIC GRAVITY A
309. o nuts 5 to 108 in Ib 12 N m 3 For Carryall 2 252 and 6 Turf 2 252 XRT 900 and Transporter 4 and 6 vehicles Place new heat shrink tubing 6 CC P N 1017189 over the short AC cord and connect the short AC cord to the retract able cord reel Figure 9 22 Page 9 32 Slide the tubing over the connection and carefully apply heat to shrink it 4 Connect the batteries See Connecting The Batteries on page 1 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 31 E IQ PLUS CHARGER ONBOARD VILLAGER 6 VILLAGER 8 Onboard Charger Removal and Installation To AC Cord Reel W de Route behind batteries TRANSPORTER 4 TRANSPORTER 6 CARRYALL 6 o Os TK TURF 2 AND 252 CARRYALL 2 AND 252 XRT 900 D eO al yl eO SN Ge ji Figure 9 22 Onboard Charger Mounting Details Page 9 32 2008 2011 Domestic Battery Charger Maintenance and Service Manual SECTION 10 HIGH FREQUENCY CHARGER ONBOARD A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 GENERAL INFORMATION This section include
310. ock IQ Plus battery charger DC plugs have three pins rather than two blades common on most standard charger plugs Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead that is the communication link between the charger and the onboard computer When the charger plug is plugged into the vehicle receptacle the onboard computer locks out the vehi cle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge IQ Plus vehicles with IQ Plus chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service unplug the charger DC cord wait 15 seconds for the computer to reset and plug the charger back in See following WARNING This will ensure the batter ies are at their optimum charge prior to returning the vehicle to service A WARNING The charger plug must be pulled slowly from the receptacle Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode BATTERY WARNING LIGHT IQ Plus vehicles feature a dash mounted battery warning light above the steering column that when the vehicle is in operation indicates low battery vo
311. ode has failed the entire heatsink must be replaced To check diodes 1 Disconnect AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 3 Remove the charger cover 4 Disconnect one transformer secondary coil wire from the diode terminal Figure 9 9 Page 9 14 5 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 9 9 Page 9 14 6 Reverse test probes and check each diode again and note the reading Figure 9 10 Page 9 14 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 7 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 Ib 2 5 N m 8 Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION f connections are not clean and tight excessive heat will be created and
312. off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle charger receptacle 2 Wait 20 seconds then reconnect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the vehicle has been driven even if only a few feet the onboard computer will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle continues If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 3 9 Page 3 11 and Figure
313. olt Batteries The following information represents a few examples of troubleshooting battery problems Example 1 Vehicle no 68 was suspected of having a bad battery due to its performance As a result the battery charger test was performed After a full charge the battery charger ammeter read 8 0 amps Next the on charge volt age test was performed and the following results were recorded BATTERY NO 1 2 3 4 On Charge Voltage 15 22V 15 90 V 14 70 V 15 24 V Battery no 3 appears suspect Battery nos 1 and 4 are also suspect Next a hydrometer test flooded lead acid batteries only or discharge test should be conducted on all batteries Hydrometer test results BATTERY NUMBER CELL NUMBER 1 2 3 4 Cell 1 Positive Post 1 200 1 265 1 300 1 250 Cell 2 1 285 1 275 1 290 1 270 Cell 3 1 265 1 270 1 275 1 265 Cell 4 Negative Post 1 275 1 270 1 285 1 265 Cell 5 1 270 1 265 1 280 1 270 Cell6 1 275 1 280 1 280 1 260 After the hydrometer test it appears that battery no 1 is the problem Next the discharge test was per formed Discharge test results BATTERY NO 1 2 3 4 Discharge Voltage 8 16 V 10 99 V 11 60 V 10 72 V After a discharge test which lasted 45 minutes battery no 1 is clearly shown to be the problem Battery no 4 should be watched a little more closely but appears to be okay
314. om the control board 6 Using a multimeter set for 200 ohms place the red probe on the red wire of the DC cord Test for con tinuity on each of the wires on the other end of the DC cord The tester should indicate continuity on the red DC cord wire only If any other reading is obtained the DC cord must be replaced Place the red probe on the blue wire of the DC cord Test for continuity on each of the wires on the other end of the DC cord The tester should indicate continuity on the blue DC cord wire only If any other reading is obtained the DC cord must be replaced Place the red probe on the black wire of the DC cord Test for continuity on each of the wires on the other end of the DC cord The tester should indicate continuity on the black DC cord wire only If any other reading is obtained the DC cord must be replaced Page 4 22 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Test Procedures Transformer The PowerDrive battery charger transformer has two sets of coils a primary coil and a secondary coil Figure 4 17 Page 4 18 Primary Coil 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 2 Remove the charger cover 3 Disconnect terminals from transformer tan primary coil transformer wires 4 and 6 Figure 4 17 Page 4 18 4 Place the continuity te
315. om the vehicle charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 3 7 Page 3 9 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected See following WARNING A WARNING Do not rock or bend the DC plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 3 7 Page 3 9 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diag nostic program ammeter will drop to zero See following NOTE NOTE Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on cha
316. on A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle The battery charger DC plug must be pulled slowly from the receptacle Figure 3 7 Page 3 9 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 3 8 Page 3 9 Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use Each charger should have its own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result in an electrical shock Do not use an adapter to plug charger into a two blade outlet
317. on page 9 22 3 Remove the charger cover 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 black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 9 21 Page 9 30 See following DANGER A 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 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 9 31 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 29 EN IQ PLUS CHARGER ONBOARD Charging a Battery Pack that has Low Voltage 6 T Plug the AC cord into an electrical outlet The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire After one or two hours disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 Disconnect the transformer wire 4 from AC circuit breaker and connect it to the relay Connect the short black wire 3 from the control boa
318. or battery chargers and to protect the vehicles and battery chargers from damage resulting from improper service or maintenance the procedures in this manual must be followed It is important to note that throughout this manual there are statements labeled DANGER WARNING or CAU TION These special statements relate to specific safety issues and must be read understood and heeded before proceeding with procedures There are also statements labeled NOTE which provide other essential service or maintenance information A DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death A CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury or product or property damage CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNING The following safety statements must be heeded whenever the vehicle or battery charger is being operated repaired or serviced Service technicians should become familiar with these general safety statements which can be found throughout this manual Also other specific warnings appear throughout this manual and on the vehicle and battery charger A DANGER Battery Explosiv
319. ould be between 105 and 128 volts If proper voltage is not present have building wiring checked by a licensed electrical contractor 5 Check continuity of the AC circuit 5 1 Remove the charger cover 5 2 Bypass the relay See step 4 of Charging a Battery Pack that has Low Voltage on page 7 34 See following DANGER A 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 3 With relay bypassed there should be continuity across the AC cord blades Figure 7 17 Page 7 19 Figure 7 17 AC Cord Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 19 POWERDRIVE 3 MODEL 26580 Test Procedures 6 If the circuit is not complete check the wiring of the AC cord transformer primary coil wires and internal AC circuit breaker Figure 7 22 Page 7 25 7 f 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 7 24 8 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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
320. ould cause batteries to explode Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not connect a stationary charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged or does not make a good electrical connection Fire or personal injury can result Have a qualified technician replace the parts Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death WARNING CONTINUED ON NEXT PAGE Page 8 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL External Charger Installation and Operation E Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the cha
321. oward the transformer to remove the fuse from the mounting tab Remove the two nuts securing the two wires to the fuse terminals and remove the fuse Fuse Link Installation 1 Connect the short brown wire from the rectifier to one of the fuse terminal posts and install the nut Tighten nut to 23 in Ib 2 6 N m Connect the DC cord black wire to the other fuse terminal post and install the nut Tighten nut to 23 in Ib 2 6 N m Gently press the fuse assembly into the mounting tab so that the fuse link is visible from the rear of the charger Install the charger cover 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 31 ES POWERDRIVE 3 MODEL 26560 Charger Repairs RELAY BOARD ASSEMBLY See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 Relay Board Assembly Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover 2 3 Disconnect all wires from the relay Figure 6 9 Page 6 11 4 Remove two screws attaching relay to the front of the charger case 5 Remove the relay Relay Board Assembly Installation Install in reverse order of removal and tighten screws firmly Connect wires as shown Figure 6 9 Page 6 11 CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 AC Circuit Breaker Removal 1 Disconnect AC cord from the wall outlet and DC plug f
322. ower for the secondary coil the transformer is shorted internally and must be replaced Figure 3 22 Page 3 23 10 Ifthe voltage reading is normal 86 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 3 21 11 When troubleshooting and repairs are complete properly connect relay wiring See following WARN ING A 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 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and then reconnect it The ammeter should jump to a reading between 14 and 18 amps and then taper to below 5 amps within 15 minutes 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Onboard Computer on page 3 19 See following NOTE 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 23 ES POWERDRIVE CHARGER EXTERNAL Test Procedures NOTE Batteries near the end of their u
323. page 10 22 If a fault occurs count the number of red flashes on the charger or dash between pauses and refer to the table below HIGH FREQUENCY BATTERY CHARGER TROUBLESHOOTING GUIDE RED FLASHES CAUSE SOLUTION Battery High Voltage Ensure battery set is rated 48 volts and composed of 24 cells See Test Procedure 1 Battery Voltage Using Multimeter on page 10 10 If not replace with correct battery set Reset charger interrupt AC power for 15 seconds Battery Low Voltage Ensure battery set is rated 48 volts and composed of 24 cells Also check the voltage of each individual battery See Test Procedure 1 Battery Voltage Using Multimeter on page 10 10 If not replace with correct battery set Reset charger interrupt AC power for 15 seconds JOK Charge Timeout caused by battery pack not reaching required voltage Charger output was reduced due to high temperatures Check for loose or corroded connections Check for old or defective batteries See Test Procedures on page 10 10 Operate charger at a lower ambient temperature sO Check Battery battery could not be trickle charged up to minimum voltage Check for shorted or damaged cells See Test Procedure 1 Battery Voltage Using Multimeter on page 10 10 sO Over Temperature Charger shut down due to high internal temperature Check for dirty obstructed or damaged cooling fins Clean if necessary and ensure
324. perly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 8 Install the charger cover and check charger for proper operation AMMETER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 Ammeter Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord red wire 1 and the white wires 2 and 3 from the ammeter 4 Figure 6 25 Page 6 31 4 Press the locking tabs on each side of the ammeter and remove the ammeter by gently pushing the ammeter through the front of the charger case Ammeter Installation 1 Place the ammeter 4 in position in the charger face and ensure that the locking tabs are secure Figure 6 25 Page 6 31 2 Connect the DC cord red wire 1 and the white wires 2 and 3 to the ammeter terminals 3 Install the charger cover 4 Plug the charger into the vehicle and check ammeter for proper operation Page 6 30 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Charger Repairs EN Figure 6 25 Ammeter FUSE LINK See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 Fuse Link Removal 1 2 3 4 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Gently press the fuse t
325. pin is a sensing lead that is the communication link between the charger and the onboard com puter When the charger plug is plugged into the vehicle receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger See following WARNING Long Term Storage Charge Vehicles with PowerDrive chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service unplug the charger DC cord wait 15 seconds for the computer to reset and plug the charger back in See following WARNING and CAUTION This will ensure the batteries are at their optimum charge prior to returning the vehicle to service A WARNING The charger plug must be pulled slowly from the receptacle Figure 3 7 Page 3 9 Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode Figure 3 8 Page 3 9 CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and ensure the charger is operating correctly during storage BATTERY WARNING LIGHT IQ System and Excel System vehicles feature a dash mounted battery warning light above the steering col umn that
326. plug The tester should indicate continuity on only one flat blade If any other read ing is obtained the AC cord and plug must be replaced 200 OHM SETTING Figure 3 23 AC Cord and Plug Continuity Test DC Cord Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 3 24 Page 3 27 Disconnect the red wire of the DC cord from the heatsink Page 3 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL 10 11 12 13 Disconnect the blue wire from the red wire assembly that connects to the charger relay Place the clip of the continuity tester on the red wire of the DC cord 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 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 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 Move the continuity tester clip to the black wire of the DC cord Pl
327. pressor 18 gauge red wire to heat sink to 18 in Ib 2 0 N m See following NOTE NOTE The charger relay blade connector is located off center within the relay housing When connecting voltage suppressor slip on connector to relay blade connector make sure slip on connector is positioned so that flat side of connector is closest to relay housing Figure 3 27 Page 3 33 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 31 POWERDRIVE CHARGER EXTERNAL Charger Repairs CHARGER RELAY See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Charger Relay Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect all wires from the relay Figure 3 27 Page 3 33 4 Remove two nuts and lock washers attaching relay to the charger case 5 Remove the relay Charger Relay Installation 1 Install in reverse order of removal Connect wires as shown Figure 3 27 Page 3 33 Tighten nut secur ing relay to charger base to 18 in Ib 2 0 N m CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 AC Circuit Breaker Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the two black wires attached to the AC circuit breaker Figure 3 27 Page 3 33 4 With a pair of pliers squeeze in the reta
328. primary coil wires 4 and 6 Figure 9 11 Page 9 16 4 Place the continuity test probes on the disconnected primary transformer coil wires The tester should indicate continuity If tester does not indicate continuity replace the transformer Secondary Coil 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 2 Remove the charger cover 3 Remove the transformer tan secondary coil wire 1 from the upper terminal of the heatsink Figure 9 11 Page 9 16 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 9 11 Page 9 16 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 Relay 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 2 Remove the charger cover 3 Remove black wires from contact terminals of the relay Figure 9 11 Page 9 16 Place continuity test probes on contact terminals of the relay The tester should indicate no continuity If tester indicates con tinuity the relay contacts have failed closed and the
329. probe check for continuity on both flat blades and on the round pin of the AC plug The tester should indicate continuity on only the round pin If any other reading is obtained the AC cord and retractable cord reel must be tested inde pendently of each other 10 Disconnect the AC cord white wire 4 from the primary coil tan wire Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord and retract able cord reel must be tested independently of each other 11 Ifthe correct readings are obtained in all of the previous steps the short AC cord is functioning properly Proceed to the following test procedure to test the retractable cord reel Retractable Cord Reel Check continuity of the AC cord and retractable cord reel at the same time 1 Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 3 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 9 13 Page 9 18 4 Disconnect the short AC cord from the retractable cord reel 5 Using a multimeter set for 200 ohms place the red probe in one of the flat blade openings of the cord reel receptacle 1 Figure 9 15 Page 9 20 Test for
330. probe to battery no 4 2 BLACK probe to battery no 4 4 4 Style C 6 x 8 Volt Precedent only With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 6 16 Page 6 18 Figure 6 16 Battery Voltage Test Precedent Style C Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 5 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 6 34 Page 6 18 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Test Procedures EN TEST PROCEDURE 2 ONBOARD COMPUTER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 1 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to This will ensure that AC power is present 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Insertthe DC cord from the second c
331. qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 1 With the charger DC cord disconnected from the vehicle charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger Page 5 6 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Charger Installation and Operation E 2 Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 5 4 Page 5 5 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected See following WARNING A WARNING Do not rock or bend the DC plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 5 4 Page 5 5 3 All vehicles except Precedent 10 to 20 seconds after the charger activates it will shut off again
332. r Club Car representative If the specified test procedures identify no problems plug the AC cord into the wall outlet and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts DC START CHARGE CYCLE 1 Disconnect the AC plug from the wall outlet 2 Wait 20 seconds then reconnect the AC cord to the wall outlet See following NOTE 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 5 E IQ PLUS CHARGER ONBOARD Troubleshooting NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TESTING CHARGER OPERATION 1 Connect the AC power supply cord to a 120 volt AC 60 hertz single phase outlet The charger relay should not close immediately but should close with an audible click after a delay of 2 to 15 seconds See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is
333. r connection between plug and receptacle Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 6 16 DC plug and cord Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 6 16 and Test Procedure 5 Charger DC Circuit Continuity Test on page 6 21 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 6 19 Gray sense lead fuse is blown not applicable to Precedent vehicles Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 6 16 Receptacle fuse link is blown not applicable to Precedent vehicles See Electrical Components section in the appropriate maintenance and service manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 6 19 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 6 19 Transformer primary coil Test Procedure 6 Transformer on page 6 22 Relay Test Procedure 8 Continuity on page 6 23 Failed ammeter Replace ammeter Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 8 Continuity on page 6 23
334. r if the charger has received a sharp blow been dropped or otherwise damaged in any way Refer all repair work to the manufacturer or qualified personnel DANGER CONTINUED ON NEXT PAGE Page 10 4 2008 2011 Domestic Battery Charger Maintenance and Service Manual HIGH FREQUENCY CHARGER ONBOARD Onboard Charger Operation This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play with the appliance A WARNING The high frequency battery charger is programmed with an algorithm that matches the type and design specifications of the batteries originally installed in the vehicle Never use this charger to charge batteries of a different type and design specification Doing so will damage the non matching batteries and greatly reduce their life span If the batteries can not be replaced with the same as original the charger must be replaced with one that matches the replacement batteries See Battery Charger Identification on page 2 1 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery in accordance with all environmental laws or return to an authorized Club Car dealer Frozen batteries can explode Only trai
335. r operation ssssssssssss 10 4 electrical system charge circuit cierre ine 10 4 general information sesssssss 10 1 test procedures 1 battery voltage sss 10 10 2 battery condition using charger 10 10 3 on charge battery voltage 10 10 4 hydrometer test esses 10 11 5 discharge test ssssssssssss 10 14 troubleshooting aeee 10 9 12 volt battery troubleshooting examples 10 19 2008 2011 Domestic Battery Charger Maintenance and Service Manual 6 volt battery troubleshooting examples 10 21 8 volt battery troubleshooting examples 10 20 IQ Plus charger external AC circuit breaker charger see circuit breaker AC cord installation 5 tente 8 28 removal 2 2 31 ities ees deine 8 28 testing 1 5 hue Re eles 8 20 ammeter installation 5 2 dike hee ees 8 26 TEMOVAL ES 8 26 TESTING 8 22 batteries battery condition after a charge cycle 8 8 charging batteries that have low voltage 8 29 state of charge test ssssssssss 8 19 battery charger operation shee tei ciet esefe iei oeed quote cud 8 5 Tepas nee eG EHE ed 8 23 TESTING e 8 8 battery condition after a charge cycle 8 8 breaker charger circuit see circuit breaker
336. r operation 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 25 EB IQ PLUS CHARGER ONBOARD Charger Repairs FUSE LINK See General Warning Section 1 Page 1 1 Fuse Link Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 2 Remove the charger cover 3 Remove both black secondary coil transformer wires and the buss bar from the back of the fuse link 4 assembly Figure 9 18 Page 9 25 Remove screws from the front of the charger and remove the fuse link assembly Fuse Link Installation 1 Place clear plastic cover over fuse assembly and install mounting screws from front of charger face The center branch of the fuse assembly should be in the upper left corner when viewed from the front of the charger Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 9 18 Page 9 25 Tighten to 22 in Ib 2 5 N m Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tighten to 22 in Ib 2 5 N m Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 9 31 Check charger for proper operation CHARGER RELAY See General Warning Section 1 Page 1 1
337. r output is low Failed diodes Test Procedure 4 Diodes on page 7 20 Transformer coil short circuit failure Test Procedure 6 Transformer on page 7 23 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 7 19 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 7 19 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 7 19 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 7 24 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Onboard Computer on page 7 19 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 7 24 Failed transformer Test Procedure 6 Transformer on page 7 23 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 7 19 Onboard computer malfunction Te
338. r reading is obtained the cord reel must be replaced 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 21 POWERDRIVE CHARGER ONBOARD Test Procedures 200 OHM SETTING Figure 4 21 Retractable Cord Reel Test Place the red probe into the other flat blade opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the cord reel must be replaced Place the red probe into the top center opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on only the round pin If any other reading is obtained the retractable cord reel must be replaced If the correct readings are obtained in all of the previous steps the retractable cord reel is functioning properly DC Cord 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 4 22 Page 4 24 4 Disconnect the red wire of the DC cord from the heatsink 5 Disconnect the blue wire fr
339. rd connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 4 19 Page 4 20 4 Disconnect the short AC cord from the retractable cord reel 5 Remove the charger cover 6 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 4 20 Page 4 21 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 19 POWERDRIVE CHARGER ONBOARD Test Procedures Figure 4 18 AC Cord and Retractable Cord Reel Continuity Test FW eR NS Bs Figure 4 19 Heatshrink Removal Page 4 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Test Procedures Figure 4 20 Short AC Cord Test 7 Disconnect the black wire 1 of AC cord from charger AC circuit breaker 8 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the short AC cord must be replaced 9 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug The tester should indicate continuity on only the round pin If any other reading is obt
340. rd from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 8 Disconnect the transformer wire 4 from AC circuit breaker and connect it to the relay Connect the black wire 3 from the relay to the AC circuit breaker Figure 6 26 Page 6 35 See following WARNING A 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 9 Install the charger cover and the retaining screws Page 6 34 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Charging a Battery Pack that has Low Voltage EN 10 Plug the DC cord into the charger receptacle and plug the AC cord into an electrical outlet 11 Allow the charger to continue charging the batteries until the charger shuts off automatically 12 When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual TRANSFORMER 9 WHITE a TAN TAN BLACK GREEN b BLACK AC PRIMARY SECONDARY f 7 AMMETER DC CORD e CIRCUIT COIL COIL D AC CORD
341. rd to the AC circuit breaker Figure 9 3 Page 9 6 See following WARNING A WARNING 10 11 12 13 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 Install charger cover and install charger in vehicle See Onboard Charger Installation on page 9 31 Plug the AC cord into an electrical outlet Allow the charger to continue charging the batteries until the charger shuts off automatically When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual DC CORD TAN H DIODES jo it CO HEATSINK DH JAZZ Figure 9 21 IQ Plus Onboard Charger Wiring Diagram Relay Bypassed Page 9 30 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Onboard Charger Removal and Installation EN ONBOARD CHARGER REMOVAL AND INSTALLATION See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required be
342. rd to the relay board assembly 2 6 N m See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m RECTIFIER NOTE This Powerdrive 3 Model 26560 uses a rectifier mounted to an aluminum heat sink plate A running change replaced the rectifier with two diode heatsink assemblies The model number changed to 26580 See Section 7 PowerDrive 3 Model 26580 Rectifier Removal Qr BS w d Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove all four wires from the rectifier 1 Figure 6 24 Page 6 28 Gently press the fuse link 2 toward the transformer to remove it from its mounting tab Remove the screws 3 securing the rectifier heatsink assembly 4 to the charger case Figure 6 24 Rectifier Heatsink Assembly Page 6 28 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Charger Repairs EN Rectifier Installation 1 Place the rectifier heatsink assembly 4 against the charger case and secure with the scr
343. re tan Disconnect the two tan secondary coil transformer wires from the heatsink Figure 4 4 Page 4 6 Disconnect the two black secondary coil transformer wires from the fuse Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in Ib 3 2 N m Figure 4 4 Page 4 6 Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect one secondary coil transformer wire black to one terminal of the fuse assembly Tighten nut to 22 in Ib 2 5 N m Connect the other secondary coil transformer wire black to the remaining terminal of the fuse assembly Tighten nut to 22 in Ib 2 5 N m 6 Connect the black primary coil transformer wire to the charger relay 7 Connect the other primary coil transformer wire to the control board 8 Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING 10 Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Install the charger cov
344. re endete 9 14 9 20 diodes charger see heatsink electrical system charge clreult 2 2 iet eee 9 2 fuse link installation ener nite 9 26 removal eniin 9 26 heatsink installation niiin iiien 9 23 removal 4 5 m EAE 9 23 testing uini eere OE ID a Hr EE es 9 13 relay installation seseeseessesseeen 9 27 removal RR HUNE 9 26 testirigr ii e REOR RR IMEEM ME 9 21 retractable AC cord reel installation aE E 9 28 removal EEA A Nici T 9 28 testing crece teet ias 9 19 test procedures 1 low battery voltage i e 9 9 2 s control board 2 n me eii 9 11 3 AC cord continuity check 9 12 3 AC DOWOE iieri inerte nen e ice 9 12 4 diodes eae ee 9 13 5 DC circuit continuity test 9 14 6 transformer sess 9 15 7 battery state of charge 9 17 8 continuity AC circuit breaker internal 9 21 AC cord with retractable cord reel 9 17 AC cord without retractable cord reel 9 18 amimieler 3 Deis ar e teens 9 21 DG OF Quentin 9 20 relay 5 tee PE SEI iate 9 21 retractable cord reel sssesssss 9 19 transformer eeseeseeeeeeennnen 9 21 Page i 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual INDEX transformer instalation 2 gere tents 9 24 removal Ut 9 24 t
345. re on page 8 16 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 8 2 Page 8 3 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 8 5 Page 8 9 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 Onrare 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 Ib 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 CIR
346. rect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals AC power interrupted Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 13 Onboard computer malfunction Test Procedure 2 Control Board on page 4 12 Charger failure See Testing Charger Operation on page 4 6 16 hour time out See Battery Warning Light on page 4 2 Battery or batteries need to be replaced See Section 13 Batteries in the appropriate maintenance and service manual Batteries are getting close to full discharge capacity Recharge batteries as soon as possible TEST PROCEDURES See General Warning Section 1 Page 1 1 INDEX OF TEST PROCEDURES Battery Voltage Control Board Diodes Transformer Battery State of Charge Test ON DOO BP OMN gt Continuity 2008 2011 Domestic Battery Charger Maintenance and Service Manual Charger DC Circuit Continuity Test AC Power and Continuity Check of AC Circuit Page 4 9 POWERDRIVE CHARGER ONBOARD Test Procedures TEST PROCEDURE 1 BATTERY VOLTAGE See General Warning Section 1 Page 1 1 Test Procedure 1A DS Villager 4 1 Check the wire connections between the vehicle and battery charger Figure 4 2 Page 4 3 1 1 Verify that the 10 gauge red wire of the charger is connected to the positive post of battery no 1 1 2 Verify the
347. relief bushing and AC cord into the mounting hole in the charger face Install the charger cover 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 33 Charger Repairs POWERDRIVE 3 MODEL 26580 Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger See following WARNING A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 7 9 Page 7 11 and Figure 7 10 Page 7 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle e Remove the screws securing the charger cover and remove the cover from the charger To apply AC power directly to the transformer primary coil the relay must be bypassed To bypass the relay remove the black wire 3 from the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 7 25 Page 7
348. rent will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 6 9 Page 6 11 and Figure 6 10 Page 6 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Page 6 12 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Troubleshooting EN Use the following Troubleshooting Guide for troubleshooting PowerDrive 3 external battery chargers model numbers 26560 11 26560 18 and 26560 19 The Troubleshooting Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages POWERDRIVE 3 BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected Connect the batteries See Connecting The Batteries on page 1 4 Battery voltage is too low Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 6 16 Poo
349. require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CC P N 101831801 See Communication Display Module in Section 11 of the appropriate mainte nance and service manual TESTING CHARGER OPERATION 1 With the DC plug disconnected from the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 2 Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle The charger relay should close with an audible click after a 2 to 15 second delay See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate in
350. res 3 and 4 from contact terminals of the relay Figure 6 9 Page 6 11 Place conti nuity test probes on contact terminals of the relay The tester should indicate no continuity If tester indi cates continuity the relay contacts have failed closed and the relay must be replaced 4 Place continuity test probes on contact terminals of relay With batteries connected insert DC plug into receptacle The tester should indicate continuity If tester does not indicate continuity relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the white wire from the left ammeter terminal as viewed from inside the charger 4 Place the continuity tester clip on one of the ammeter posts 5 Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker E no Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the wires from the AC circuit breaker Place the continuity test probe on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuity replace the AC circuit breaker Page 6 26 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Charger Repairs EN
351. resent 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 Ifthe 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 Ifthe 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 A 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
352. rge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CC P N 101831801 See Communication Display Module in Section 11 of the appropriate mainte nance and service manual If charger does not appear to be operating properly or if the batteries appear to be weak contact your Club Car distributor dealer Page 3 10 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Charger Installation and Operation EJ TESTING CHARGER OPERATION 1 With the DC plug disconnected from the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 2 Disconnect the AC cord from the wall outlet and connect the D
353. rger Identification on page 2 1 The charger can display its algorithm number by initiating Algorithm Display Mode To enter Algorithm Display Mode do the following 1 Unplug the AC power supply cord from the wall outlet 2 Disconnect the heavy gauge red wire from the positive post of battery no 1 3 Plug the AC power supply cord into the wall outlet See following NOTE NOTE When the charger AC cord is connected LED lights on the charger and dash perform start up self test LEDs light up in sequence 4 Afterthe start up self test the 8096 LED will display a series of flashes that represent the algorithm num ber Figure 10 2 Page 10 3 Example Algorithm number 125 is represented as one flash pause two flashes pause five flashes The charger will not repeat this series of flashes To see the number again repeat steps 1 and 3 with a 20 second pause between them 94 Figure 10 2 80 LED Flashes in Algorithm Display Mode 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 3 HIGH FREQUENCY CHARGER ONBOARD The Charge Circuit THE CHARGE CIRCUIT The charge circuit consists of the onboard charger batteries and charger information light Figure 10 3 Page 10 4 SOLID STATE SPEED I gt B CONTROLLER SY TERMINAL I ml z NN Ii l To Main wl TUIS Vehicle HH WRR Harness WE Charger 14 GA BLACK Information Light To Main Vehicle
354. rger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts that secure the heatsink to the case Tighten the bolts to 22 in Ib 2 5 N m Figure 4 4 Page 4 6 2 Connectthe red wire from the DC cord and the red wire from the control board to the center terminal post on the heatsink Tighten nut to 18 in Ib 2 0 N m 3 Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 4 Connect the other secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 34 6 Check charger for proper operation 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 25 POWERDRIVE CHARGER ONBOARD Charger Repairs TRANSFORMER See General Warning Section 1 Page 1 1 Transformer Removal 1 Doo RON Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 Remove the charger cover Disconnect the black primary coil wire from the charger relay Figure 4 4 Page 4 6 Disconnect the tan primary coil wire from the control board Remove the wire tie that secures the DC cord wire to the secondary coil wi
355. rger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes A CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and ensure the charger is operating correctly during storage NOTE Charger operation instructions in the language of the user should be printed on or permanently affixed to the top of the charger If these instructions are not found on the charger contact your Club Car representative EXTERNAL CHARGER AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions With charger DC output cord disconnected connect the power supply cord to an AC supply See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances The use of an extension cord with
356. ries need to be replaced See Batteries section in the appropriate maintenance and service manual Page 3 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Troubleshooting PRIMARY COIL GREEN GROUND TAN WIRE TO WIRE W PRIMARY COIL BLACK WIRE TO CIRCUIT BREAKER BLACK WIRE TO RED WIRE RELAY OF DC CORD f RED WIRE TO RELAY J Dre S 7 SECONDARY COIL Z SUF oy IU PRIMARY GOIL WIRES TAN ex SECONDARY COIL WIRES BLACK DC CORD BLACK RED WIRE TO HEATSINK WIRE TO AMMETER Figure 3 10 PowerDrive Battery Charger 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 15 E POWERDRIVE CHARGER EXTERNAL Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 INDEX OF TEST PROCEDURES Battery Voltage and DC Plug and Receptacle Onboard Computer AC Power and Continuity Test of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test ON DOOR WD Continuity TEST PROCEDURE 1 BATTERY VOLTAGE AND DC PLUG AND RECEPTACLE See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 1 Check the DC plug and the vehicle charger receptacle for damage dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspectthe receptacle contacts to ensure that they are not damaged and th
357. rom the vehicle receptacle 2 Remove the charger cover 3 Disconnect the two black wires attached to the circuit breaker Figure 6 9 Page 6 11 4 With a pair of pliers squeeze in the retaining tabs on the sides of the circuit breaker and push the circuit breaker through the mounting hole in the face of the charger to remove AC Circuit Breaker Installation Install in reverse order of removal CHARGER AC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 AC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the AC cord black wire 1 from the AC circuit breaker 3 Figure 6 22 Page 6 24 4 Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan pri mary coil wire Figure 6 22 Page 6 24 e Disconnect the AC cord white wire 4 from the primary coil tan wire 6 Disconnect the AC cord green wire 2 from the charger base 7 Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger Page 6 32 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Charger Repairs EN AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Connect the AC cord black wire 1 to the AC circuit brea
358. roper AC line voltage Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 13 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 13 Failed AC cord reel Test Procedure 8 Continuity on page 4 19 Internal AC breaker Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 13 Transformer primary coil Test Procedure 6 Transformer on page 4 17 Relay Test Procedure 8 Continuity on page 4 19 Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 4 Diodes on page 4 14 Both Diodes failed Test Procedure 4B Both Diodes Failed on page 4 15 Onboard computer malfunction Test Procedure 2 Control Board on page 4 12 Failed transformer Test Procedure 6 Transformer on page 4 17 Failed ammeter Replace ammeter Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 4 19 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 4 14 Loose internal fuse connection Tighten connection Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B Bo
359. roperly insulate electrical connections in the charger could result in a short circuit 6 Connect the green wire to the charger base Tighten the screw and nut on the green ground wire ter minal to 18 in Ib 2 0 N m 7 Position the strain relief bushing on the AC cord 8 Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 9 Install the charger cover CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger See following WARNING 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 29 E POWERDRIVE 2 CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 5 6 Page 5 8 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 3 Remove the screws securing the charger cover and remove the cover from the charger 4 To apply AC power
360. ropriate for your battery charger If you do not have this publication contact your Club Car representative If the specified test procedures identify no problems plug the DC cord into the vehicle and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts DC START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle charger receptacle 2 Wait 20 seconds then reconnect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TESTING CHARGER OPERATION 1 With the DC plug disconnected from the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 2 Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle The charger relay should close with an audible click after a 2 to 15 second delay See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If
361. rvice Manual Page 7 15 POWERDRIVE 3 MODEL 26580 Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 INDEX OF TEST PROCEDURES Battery Voltage and DC Plug and Receptacle Onboard Computer AC Power and Continuity Test of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test ON DOOR WD Continuity TEST PROCEDURE 1 BATTERY VOLTAGE AND DC PLUG AND RECEPTACLE See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 1 Check the DC plug and the vehicle charger receptacle for damage dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspectthe receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 DS vehicles Verify that the 10 gauge red wire from the charger receptacle is connected to the pos itive post of battery no 1 Figure 7 3 Page 7 4 3 2 Make sure the two nuts that secure the two 10 gauge black wires to the receptacle fuse assembly are tight Figure 7 11 Page 7 16 CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER SENSE LEAD FUSE Figure 7 11 Receptacle Wire Connections all vehicles except Precedent 3 3 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sen
362. s Place multimeter red 4 probe here 7 FRONT OF VEHICLE 4 TURF 2 252 VEHICLES CARRYALL 2 252 VEHICLES 5 f XRT 900 VEHICLES Itimeter CARRYALL 6 VEHICLES STYLE B Place mu black probe here Place multimeter red 4 probe here VILLAGER 6 AND 8 VEHICLES FRONT Z Place multimeter OF VEHICLE black probe here Place multimeter Place multimeter red probe here black probe here T VEHICLES CARRYALL 6 VEHICLES STYLE A Figure 8 8 IQ Plus Battery Configuration Page 8 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Test Procedures EN TEST PROCEDURE 2 ONBOARD COMPUTER See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 1 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to This will ensure that AC power is present 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Insertthe DC cord from the second charger into the receptacle of the vehicle that is not charging properly 4 Ifthe second charger fails in the same manner as the first charger then the vehicle charging circuit is not functioning properly See Troubleshooting on page 8 9 5 Connectthe first charger into another vehicle that is known to be functioning
363. s and ordinances The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 meters Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Be sure the fuse link is clean and tight not applicable to Precedent vehicles Be sure all wire connections at the receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 5 4 Page 5 5 Do not pull on the DC cord Figure 5 5 Page 5 5 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a
364. s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual Page 8 30 2008 2011 Domestic Battery Charger Maintenance and Service Manual SECTION 9 IQ PLUS CHARGER ONBOARD A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 GENERAL INFORMATION This section includes information pertaining to service of the onboard IQ Plus battery charger model numbers 25260 11 and 25260 50 as installed in IQ Plus vehicles For battery charger models other than those listed above refer to the appropriate section in the appropriate battery charger maintenance and service manual Do not attempt to service a battery charger that has not been properly identified If a charger cannot be prop erly identified contact your local Club Car dealer or distributor For battery chargers with model numbers listed above that are installed in vehicles other than IQ Plus vehi cles contact your local Club Car dealer or distributor The IQ Plus battery charger is automatic and has no external controls Figure 9 1 Page 9 1 When the charger is connected there is a 2 to 15 second delay before charging begins See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Chargi
365. s information pertaining to service of the High Frequency battery charger model number 912 4852 Do not attempt to service a battery charger that has not been properly identified If a charger can not be properly identified contact your local Club Car dealer or distributor The High Frequency Battery Charger functions as an integral part of the vehicles electrical system and will not work with other electric vehicles The charger is programmed with a specific charge algorithm that is appropriate to the specific battery type used in the vehicle See Battery Charger Identification on page 2 1 When the charger AC cord is connected LED lights on the charger and dash perform start up self test LEDs light up in sequence The charger utilizes sophisticated charge termination criterion to shut off automatically preventing the possi bility of either undercharging or overcharging The charger accomplishes this by monitoring battery voltage charge current charge time and using strict dV dt termination criterion Figure 10 1 High Frequency Battery Charger 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 10 1 HIGH FREQUENCY CHARGER ONBOARD General Information FEATURES Charge Interlock When the AC power cord is inserted into a wall receptacle the charger locks out the vehicle drive sys tem This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and c
366. s installed Ensure that the charger venti lation slots are unobstructed Normal Charger Operation 1 Connect the AC power supply cord into an AC outlet designed to provide the proper AC voltage for the charger 2 The charger will activate automatically within 2 to 15 seconds 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages that are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 Monitor the ammeter Under normal operating conditions when the charger is on and the batteries are discharged the charger will shut off in order to run a self diagnostic program ammeter will drop to zero one hour and two hours into the charge cycle See following CAUTION and NOTE CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage NOTE Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batter
367. s to the receptacle fuse assembly are tight Figure 5 8 Page 5 13 3 2 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sense lead fuse to the onboard computer gray wire A WARNING Do not bypass the sense lead fuse CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER FUSE Figure 5 8 Receptacle Wire Connections all vehicles except Precedent 3 3 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistance should be less than 2 ohms 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 13 S POWERDRIVE 2 CHARGER EXTERNAL Test Procedures Test Procedure 1 Battery Voltage and DC Plug and Receptacle Continued 4 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 5 9 Page 5 14 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 5 29 Place multimeter red probe here FRONT OF VEHICLE Place multimeter black probe here Figure 5 9 DS Battery Configuration Pr
368. se lead fuse to the onboard computer gray wire See following WARNING Page 7 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 Test Procedures A WARNING Do not bypass the sense lead fuse 3 4 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistance should be less than 2 ohms 3 5 Precedent Verify that the 10 gauge red wire from the charger receptacle is connected to the pos itive post of battery no 1 Figure 7 4 Page 7 5 4 Check battery pack voltage 4 1 DS DS Villager 4 800 810 and 850 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 7 12 Page 7 17 Figure 7 12 DS DS Villager 4 800 810 and 850 Battery Configuration 4 2 Turf 1 and Carryall 1 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 7 13 Page 7 17 Place multimeter red probe here FRONT OF VEHICLE Place multimeter black probe here Figure 7 13 Turf 1 and Carryall 1 Battery Configuration 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 7 17 POWERDRIVE 3 MODEL 26580 Test Procedures 4 3 Style A and B 4 x 12 Volt Precedent only With a mult
369. seful lives may not allow the battery charge current to taper below 5 amps See Batteries section in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 AC Cord 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 3 23 Page 3 24 4 Disconnect the black wire 1 of AC cord from charger AC circuit breaker 3 5 Disconnect the AC cord white wire 4 from the primary coil tan wire 6 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug Figure 3 23 Page 3 24 The tester should indicate continuity on only the round pin If any other reading is obtained the AC cord and plug must be replaced Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC
370. separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock An extension cord or electrical outlet must accept a three prong plug Extension cord should be a three wire no 12 AWG American Wire Gauge and be as short as possible The use of improper extension cord could result in fire or an electrical shock Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slowly Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and c
371. set TEST PROCEDURE 2 BATTERY CONDITION USING CHARGER ALL BATTERIES The easiest way to monitor the condition of a vehicle s batteries is simply to observe the Charger Information Light usually found on the dash at the end of the charge cycle After a full charge disconnect the charger AC plug wait 30 seconds and reconnect the charger AC plug The red LED in the Charger Information Light will flash quickly and then flash slowly within 10 to 20 minutes indicating sound fully charged batteries NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper and the red Charger Information Light will continue to flash quickly See Batteries Section in the appro priate maintenance and service manual Continued poor performance may indicate a problem in the vehicle electrical system brakes or battery charger If the problem is not found in the vehicle or charging system proceed to the on charge voltage test If the red LED in the Charger Information Light does not change to a slow flash the batteries should be tested further using the on charge voltage test TEST PROCEDURE 3 ON CHARGE BATTERY VOLTAGE USING CHARGER AND MULTIMETER ALL BATTERIES When the batteries are fully charged disconnect the charger DC plug Wait 20 to 30 seconds and reconnect the DC plug to restart the charger After 5 minutes use a multimeter to check and record the voltage of the battery set as well as the individual b
372. set to the diode test function connect the red test Disconnect one transformer secondary coil wire from the diode terminal Figure 3 18 Page 3 21 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 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 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 Ib 2 5 N m Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION 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 POWERDRIVE CHARGER EXTERNAL DISCONNECTED SECONDARY COIL Figure 3 18 Diode Test Figure 3 19 Diode Test Probes Reversed Test Procedure 4B
373. sonal injury or death 9 Install the charger cover and the retaining screws 10 Plug the DC cord into the charger receptacle and plug the AC cord into an electrical outlet 11 Allow the charger to continue charging the batteries until the charger shuts off automatically 12 When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual Page 5 30 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 2 CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage T AMMETER BLACK AC CIRCUIT DISCONNECTED PRIMARY SECONDARY VOLTAGE COIL COIL SUPPRESSOR BREAKER v TRANSFORMER DISCONNECTED FROM RELAY AND CONNECTED TO BREAKER m AC RECTIFIER 5 WHITE TAN TAN BLACK a Figure 5 21 PowerDrive 2 Charger Wiring Diagram Relay Bypassed 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 31 SECTION 6 POWERDRIVE 3 MODEL 26560 A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 The battery charger DC plug must be pulled slowly from the receptacle F
374. ssemblies in place of a rectifier mounted to an aluminum heat sink plate The model number with the rectifier was 26560 See Section 6 PowerDrive 3 Model 26560 Diode Heatsink Removal 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 diode heatsink being replaced Figure 7 9 Page 7 11 and Figure 7 10 Page 7 15 4 Remove the white wire from the side diode heatsink or the brown wire from the top diode heatsink depending on which diode heatsink is being replaced 5 Remove the nuts and bolts that secure the diode heatsink to the case Diode Heatsink Installation 1 Place diode heatsink against charger base Make sure clear plastic insulator sheet is between the diode heatsink and the charger base Install the nuts and bolts that secure the diode heatsink to the case Tighten the bolts to 18 in Ib 2 0 N m Figure 7 9 Page 7 11 and Figure 7 10 Page 7 15 2 Connect the white wire from the ammeter to the center terminal post on the side diode heatsink or the brown wire from the fuse link to the center terminal post on the top diode heatsink Tighten nut to 18 in Ib 2 0 N m 3 Connect the orange and purple secondary coil transformer wires 1 and 2 to the diode heatsink at the original locations Tighten nuts to 18 in Ib 2 0 N m
375. st Procedure 2 Onboard Computer on page 7 19 Charger failure See Testing Charger Operation on page 7 11 16 hour time out See Battery Warning Light on page 7 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Battery warning light illuminates for ten seconds at four second intervals with DC charger cord unplugged 25 seconds at 10 second intervals for Precedent vehicles Batteries are getting close to full discharge capacity Recharge batteries golf round may be completed first Onboard computer malfunction Test Procedure 2 Onboard Computer on page 7 19 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Page 7 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26580 FUSE LINK DIODES HEATSINK A amp NN N W I LL KK NN t LL AS NN M NN PRIMARY COIL SECONDARY COIL Troubleshooting SECONDARY COIL WIRES ORANGE AND PURPLE AMMETER RELAY BLACK WIRE TO PRIMARY COIL DC CORD BLACK WIRE TO FUSE DC CORD RED WIRE TO AMMETER BLACK WIRE TO CIRCUIT BREAKER DC CORD BLUE WIRE TO RELAY GREEN WHITE WIRE TO GROUND WIRE PRIMARY COIL Figure 7 10 PowerDrive 3 Battery Charger Components Model 26580 2008 2011 Domestic Battery Charger Maintenance and Se
376. st Procedures TAN WIRE TO PRIMARY COIL TAN WIRE TO PRIMARY COIL RED WIRE TO HEATSINK See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 INDEX OF TEST PROCEDURES Battery Voltage and DC Plug and Receptacle ON Oo 0c 2 WD Page 8 12 Onboard Computer AC Power and Continuity Test of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test Continuity 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Test Procedures EN TEST PROCEDURE 1 BATTERY VOLTAGE AND DC PLUG AND RECEPTACLE See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 1 Check the DC plug and the vehicle charger receptacle for damage dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspectthe receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 Carryall 6 Transporter 4 and 6 and Villager 6 and 8 Verify that the 10 gauge red wire from the charger receptacle is connected to the same large post of the solenoid as the 6 gauge red wire that connects to the positive post of battery no 1 Figure 8 2 Page 8 3 3 2 Carryall 2 252 Turf 2 252 and XRT 900 Verify that the 10 gauge red wire from the charger recep tacle is connected to the positive pos
377. st probes on the disconnected primary transformer coil wires The tester should indicate continuity If tester does not indicate continuity replace the transformer Secondary Coil 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 2 Remove the charger cover 3 Remove the transformer tan secondary coil wire 1 from the upper terminal of the heatsink Figure 4 17 Page 4 18 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 4 17 Page 4 18 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 Relay 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 33 2 Remove the charger cover 3 Remove black wires from contact terminals of the relay Figure 4 17 Page 4 18 Place continuity test probes on contact terminals of the relay The tester should indicate no continuity If tester indicates con tinuity the relay contacts have failed closed and the relay must
378. t 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes ONBOARD CHARGER AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions Connect the power supply cord to an AC supply See Section 2 Charger Identification and Specifica tions To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances Place the charger AC cord so it will not be stepped on tripped over or otherwise subject to damage or stress The use of an extension cord with the onboard charger must be avoided Do not place items in the compartment where the battery charger is installed Ensure that the charger venti lation slots are unobstructed CHARGING BATTERIES 1 Connect the AC power supply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 The charger will activate automatically within 2 to
379. t Procedures 2 If discharge times are low less than 60 minutes replace batteries below 5 0 volts BATTERY VOLTAGES BATTERY CONDITION 4 5 6 5 25V 5 25V 5 25 V 5 25V 525V 525V 5 25V 5 25 V Excellent 5 30 V 5 30 V 5 45 V 4 70V 5 30V 5 30 V 5 30 V 5 30 V Battery no 4 is near end of useful life 5 40 V 5 40 V 5 00 V 5 40V 4 60V 5 40 V 5 40 V 5 40 V Battery nos 3 and 5 are near end of useful life 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a charge for an entire work shift However discharge time is dependent on the elec trolyte temperature The table shown gives the discharge times at various temperatures of a set of bat teries that delivers 62 minutes at 80 F 26 7 C ELECTROLYTE DISCHARGE TIME TO ELECTROLYTE DISCHARGE TIME TO TEMPERATURE SHUT OFF POINT TEMPERATURE SHUT OFF POINT ao 40 Minutes oo i 64 Minutes e lt 6 45 Minutes 0254 lt 6 66 Minutes Gene T 50 Minutes E 68 Minutes es e 54 Minutes datei 70 Minutes 2123 Um 57 Minutes eines 72 Minutes be a 60 Minutes 5400 55 74 Minutes CHE an 62 Minutes ye eee Page 10 18 2008 2011 Domestic Battery Charger Maintenance and Service Manual Test Procedures HIGH FREQUENCY CHARGER ONBOARD BATTERY TROUBLESHOOTING EXAMPLES 12 V
380. t breaker the white wire to the primary coil and the green wire to the charger base Tighten the screw on the green ground wire terminal to 18 in Ib 2 0 N m 3 Position the strain relief bushing on the AC cord 4 Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 5 Install the charger cover 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 3 33 ES POWERDRIVE CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger See following WARNING A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 3 9 Page 3 11 and Figure 3 10 Page 3 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 3 Remove the charger cover 4 To apply AC power directly to the transformer primary coil the relay must be bypassed 4 1 To bypass th
381. t breaker through the mounting hole in the face of the charger AC Circuit Breaker Installation 1 Install in reverse order of removal CHARGER AC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 AC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the AC cord black wire from the AC circuit breaker 4 Carefully cut the heatshrink that insulates the AC cord white wire 4 where it connects to the tan primary coil wire Figure 5 17 Page 5 20 5 Disconnect the AC cord white wire 4 from the primary coil tan wire 6 Disconnect the AC cord green wire from the charger base 7 Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Connect the AC cord black wire to the AC circuit breaker Place a piece of heatshrink tubing over the AC cord white wire Connect the AC cord white wire to the tan primary coil wire Figure 5 17 Page 5 20 9v Som Slide the heatshrink tubing over the connection and apply heat to the heatshrink to insulate the connec tion between the AC cord white wire and the tan primary coil wire See following WARNING A WARNING Make sure the electrical connections are properly insulated Failure to p
382. t multimeter to 200 volts DC See following DANGER A DANGER Do not touch any wire or component in the battery charger while DC power is present Failure to heed this warning will result in an electric shock 2 Place black probe of multimeter on terminal with blue DC cord wire and red probe to terminal with red relay wire Figure 9 5 Page 9 11 Jmm UL n A BLUE WIRE RED WIRE TO DC TO RELAY CORD e NN BLACK WIRE 200 DCV SETTING 200 DCV SETTING TAN WIRE TO AC CIRCUIT TO TRANSFORMER BREAKER Figure 9 5 DC Circuit Test Figure 9 6 AC Circuit Test 3 Multimeter should indicate full battery voltage approximately 47 50 volts If reading is incorrect replace control board AC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and blue wires remain connected to vehicle Set multimeter to volts AC 2 Disconnect tan wire from transformer primary coil at terminal on control board Figure 9 7 Page 9 12 See following DANGER A 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 3 Place black probe of multimeter set to 200 volts AC onto terminal with black AC circuit breaker wire Connect red probe to terminal from which tan transformer wire was disconnected Figure 9 6 Page 9 11 4 Connect AC cord to outlet Reading should be approx
383. t of battery no 1 Figure 8 2 Page 8 3 3 3 Verify the 10 gauge red wire of the charger receptacle is connected to the main harness red wire at three wire plug 3 4 Make sure the two nuts that secure the two 10 gauge black wires to the receptacle fuse assembly are tight Figure 8 7 Page 8 13 3 5 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sense lead fuse to the onboard computer gray wire See following WARNING A WARNING Do not bypass the sense lead fuse CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER SENSE LEAD FUSE Figure 8 7 Receptacle Wire Connections 3 6 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistance should be less than 2 ohms 4 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 8 Figure 8 8 Page 8 14 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 8 29 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 13 EN IQ PLUS CHARGER EXTERNAL Test Procedure
384. te ite 3 20 5 DC circuit continuity test 3 21 6 transformer see 3 22 7 battery state of charge sss 3 23 8 continuity AC circuit breaker internal 3 26 AC cord and plug sssssssss 3 24 amimelers eer 3 26 DG Cord itecto t e pte tente 3 24 relay cee 3 26 transformer 5 3 doped Cedere terne 3 25 voltage suppressor ceecee 3 25 transformer installation 2 rette 3 29 removal Scie rees 3 29 Iul 3 22 troubleshooting eee 3 12 voltage suppressor eee 3 31 installation 1 cem eee tete 3 31 removal 2 5 2 rre E eo er Cl e e etes 3 31 TESTING oec eg as aea eness 3 25 PowerDrive charger onboard AC cord short installation teret nte 4 30 removal ir ect Red 4 29 ammeter installation 24 cect ee an 4 27 removal gvon ie even lined cities 4 27 testing ennt ree e ie etie 4 23 batteries battery condition after a charge cycle 4 6 charging batteries that have low voltage 4 31 state of charge test ssssssssssussss 4 18 battery charger charger features nene 4 2 identification irent enn 2 1 instalation ni e air rette 4 34 4 35 operation eee 4 5 removal i e a rdi Ferr ENT 4 33 4 34 repais eR E 4 24 specifications ssssssssseeeeenn 2 2 testing cc
385. tempting any repair Figure 6 9 Page 6 11 and Figure 6 10 Page 6 15 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle e Remove the screws securing the charger cover and remove the cover from the charger To apply AC power directly to the transformer primary coil the relay must be bypassed To bypass the relay remove the black wire 3 from the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 6 26 Page 6 35 See following DANGER A 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 Plug the DC cord into the charger receptacle first and then plug the AC cord into an electrical outlet 6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 7 After one or two hours disconnect the charger AC co
386. tepas nV ERE 3 27 SpeciflCatiOni szyte m cte cene tera ceed 2 2 TESTING coio iieii idii eiei 3 11 battery warning light een 3 2 breaker charger circuit see circuit breaker charge circuit 2 cete ime 3 3 circuit breaker installation ee 3 32 termoval 5 intANIMM Tie 3 32 testing keiini rete 3 26 cord charger see AC cord or DC cord DC cord IDSDectioD ree emn tnr ee 3 11 installation 1 2 2 Iren 3 28 retmoval 5 term iia hee 3 27 Ip M aia 3 21 3 24 diodes charger see heatsink electrical system charge circ it 2 1 uice tert vei cederet 3 3 fuse link installation ce 3 31 termmoval s ini NIBIENN NEN 3 31 heatsink installation 3 28 removal x eI MEHR neris 3 28 testing chs is eae ie a eee iren hee 3 20 long term storage charge 3 2 onboard computer testing u ucneisen nomen ues 3 19 relay instalatii 3 5 1 Ier ceteras 3 32 rermoval 5452 x tei nins 3 32 INDEX testing eene terere Trete ee ete ees 3 26 specification battery charger 2 2 suppressor voltage see voltage suppressor test procedures 1 faulty receptacle connection 3 16 1 low battery voltage 3 16 2 onboard computer eese 3 19 3 AC cord continuity check 3 19 3 AC POWER tete regeret dede 3 19 4 dlod8s oue Het e
387. ter mittently See Battery Warning Light on page 5 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 7 NS POWERDRIVE 2 CHARGER EXTERNAL Charger Installation and Operation Testing Charger Operation Continued 3 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 5 2 Page 5 3 and that the internal charger wiring is correct Figure 5 6 Page 5 8 DC CORD AC CIRCUIT VOLTAGE BREAKER SUPPRESSOR CASE GROUND TAN t Figure 5 6 PowerDrive 2 Battery Charger Wiring Diagram External Charger DC CORD AND PLUG INSPECTION The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See Charger Receptacle in Section 12 of the appropriate maintenance and service manual for receptacle removal and installation See also DC Cord Removal on page 5 23 See following NOTE NOTE If the warning tag has been damaged or removed from t
388. teries on page 1 4 Figure 4 29 Onboard Charger Mounting Precedent Vehicles 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 4 35 SECTION 5 POWERDRIVE 2 CHARGER EXTERNAL A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 The battery charger DC plug must be pulled slowly from the receptacle Figure 5 4 Page 5 5 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 5 5 Page 5 5 GENERAL INFORMATION This section includes information pertaining to service of the PowerDrive 2 battery charger model numbers 22110 11 22110 18 and 22110 19 Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor The PowerDrive 2 battery charger is automatic and has no external controls Figure 5 1 Page 5 1 When the charger is connected there is a 2 to 15 second delay before charging begins NOTE All vehicles except Precedent Shortly after charging begins the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge This will be repeated at one hour and at two hours into the charge cycle The onboard computer h
389. tery warning light will repeatedly illuminate for 25 seconds at 10 second intervals 10 seconds at 4 second intervals for Limo vehicles during a charge cycle with the DC plug still connected if AC power to the charger is interrupted The light will go out when AC power is restored Page 3 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL The Charge Circuit EU THE CHARGE CIRCUIT DS DS VILLAGER 4 800 810 AND 850 The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 2 Page 3 3 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger re
390. th Diodes Failed on page 4 15 Charger output is low One diode failed Test Procedure 4A Single Diode Failure on page 4 14 Transformer coil short circuit failure Test Procedure 6 Transformer on page 4 17 Onboard computer malfunction Test Procedure 2 Control Board on page 4 12 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 13 Onboard computer malfunction Test Procedure 2 Control Board on page 4 12 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 4 18 Troubleshooting Guide continued on next page Page 4 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Test Procedures POWERDRIVE ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Control Board on page 4 12 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 4 19 Failed transformer Test Procedure 6 Transformer on page 4 17 Incor
391. the DC cord and ammeter See Test Pro cedure 8 Continuity on page 5 20 Also check the rectifier See Test Procedure 4 Rectifier on page 5 16 If the multimeter indicates a voltage reading in both directions a short circuit exists in the charger DC cir cuit usually caused by a failed rectifier See Test Procedure 4 Rectifier on page 5 16 If the rectifier has not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 5 20 POSITIVE PIN DIODE SETTING Figure 5 15 DC Plug Test Probes Reversed TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 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 5 15 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the two black transform
392. the charger may become damaged 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 9 13 9 IQ PLUS CHARGER ONBOARD Test Procedures DISCONNECTED SECONDARY COIL WIRE Figure 9 9 Diode Test Figure 9 10 Diode Test Probes Reversed Test Procedure 4B Both Diodes Failed See General Warning Section 1 Page 1 1 To check the diodes use Test Procedure 4A Single Diode Failure on page 9 13 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 9 2 Page 9 3 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 control board and the DC cord black wire should be connected to the left side of the ammeter when viewed from inside the charger Figure 9 3 Page 9 6 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 o
393. the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 5 Install the charger cover and check charger for proper operation TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Transformer Removal 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the tan primary coil wire from the charger relay Figure 3 9 Page 3 11 and Figure 3 10 Page 3 15 Disconnect the AC cord white wire from the primary coil tan wire 5 Remove the wire tie that secures the DC cord wire to the secondary coil wire tan T 8 Disconnect the two tan secondary coil transformer wires from the heatsink Figure 3 9 Page 3 11 and Figure 3 10 Page 3 15 Disconnect the two black secondary coil transformer wires from the fuse Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in Ib 3 2 N m Figure 3 10 Page 3 15 2 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in Ib 2 5 N m 3 Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in Ib 2 5 N m 4 Connect one secondary coil transformer wire tan to the top ter
394. tifier could result in little or no battery charging current or a tripped AC circuit breaker 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect all four wires from the rectifier Figure 6 18 Page 6 20 RECTIFIER z RECTIFIER Figure 6 18 Rectifier Test Figure 6 19 Rectifier Test Probes Reversed Page 6 20 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Test Procedures EN 4 Using a multimeter set to the diode test function place the black probe of the multimeter on the positive terminal of the rectifier Move the positive probe to each of the remaining three rectifier terminals and note the readings Figure 6 18 Page 6 20 4 1 The multimeter should indicate approximately 922 mV with the positive probe on the negative rectifier terminal 4 2 The multimeter should indicate approximately 496 mV with the positive probe on one of the AC rectifier terminals 4 3 The multimeter should indicate approximately 496 mV with the positive probe on the other AC rectifier terminal 4 4 If any other reading is obtained the rectifier has failed and must be replaced 5 Using a multimeter set to the diode test function place the black probe of the multimeter on the negative terminal of the rectifier Move the positive probe to each of the rem
395. tion RETRACTABLE AC CORD REEL See General Warning Section 1 Page 1 1 Retractable AC Cord Reel Removal 1 Disconnect retractable AC cord from AC outlet See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 9 13 Page 9 18 3 Disconnect the short AC cord from the retractable cord reel 4 Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transporter 4 and 6 Remove four screws 1 6 securing the cord reel housing 2 and its backing plate 3 to vehicle Figure 9 20 Page 9 29 Remove hardware securing U shaped bracket 4 of retractable cord reel assembly 5 5 1 Villager 6 and 8 Remove four screws 6 securing U shaped bracket to charger 5 2 Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transporter 4 and 6 Remove four bolts 7 and locknuts 8 securing U shaped bracket to vehicle 9 Lift retractable cord reel assembly from vehicle Retractable AC Cord Reel Installation 1 2 Install in reverse order of removal Install and tighten U shaped bracket hardware securing retractable cord reel assembly 2 1 Villager 6 and 8 Tighten four screws 6 to 13 in Ib 1 5 N m 2 2 Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transporter 4 and 6 Tighten four bolts 7 and locknuts 8 to 65 in Ib 7 3 N m Carryall 2 252 Turf 2 252
396. ts own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result in an electrical shock Do not use an adapter to plug charger into a two blade outlet or extension cord Extension cord or outlet must accept grounded three blade plug The use of an improper extension cord could result in fire or electric shock Chargers can ignite flammable materials and vapors Do not use near fuels grain dust solvents thinner or other flammables Keep charger dry Do not expose to rain Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other materials to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes Page 6 8 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Charger Installation and Operation EN Note Appearance of receptacle Note Appearance of may vary depending on vehicle receptacle may vary depending on vehicle Figur
397. ttery Charger Maintenance and Service Manual Page 7 9 POWERDRIVE 3 MODEL 26580 Charger Installation and Operation A WARNING Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death With the charger DC cord disconnected from the vehicle charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 7 7 Page 7 9 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected See following WARNING A WARNING 4 Do not rock or bend the DC plug To connect the charger p
398. ttom 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 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Using a multimeter set to the diode test function place the black probe of the multimeter on the 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 Page 3 25 Test Procedures POWERDRIVE CHARGER EXTERNAL Test Procedures NOTE All vehicles except Precedent Repeated failure of sense lead fuses is a symptom of a voltage supressor that has failed in a closed condition Precedent vehicles only Failure of the onboard computer prior to Version 3 0 due to a blown internal sense lead fuse is a symptom of a voltage supressor that has failed in a closed
399. turn the vehicle to service unplug the charger DC cord wait 15 seconds for the computer to reset and plug the charger back in See following WARN ING This will ensure the batteries are at their optimum charge prior to returning the vehicle to service A WARNING The charger plug must be pulled slowly from the receptacle Figure 5 4 Page 5 5 Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode Figure 5 5 Page 5 5 BATTERY WARNING LIGHT Precedent IQ System and PowerDrive vehicles feature a dash mounted warning light above the steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger DC cord is unplugged during a charge cycle the battery warning l
400. ty across the AC cord blades Figure 6 17 Page 6 19 Figure 6 17 AC Cord Test 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 6 19 E POWERDRIVE 3 MODEL 26560 Test Procedures 6 Ifthe circuitis not complete check the wiring of the AC cord transformer primary coil wires and internal AC circuit breaker Figure 6 22 Page 6 24 7 f 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 6 23 8 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 RECTIFIER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 NOTE This Powerdrive 3 Model 26560 uses a rectifier mounted to an aluminum heat sink plate A running change replaced the rectifier with two diode heatsink assemblies The model number changed to 26580 See Section 7 PowerDrive 3 Model 26580 The rectifier converts the AC voltage from the transformer secondary coil to DC voltage This conversion is necessary since the batteries require DC voltage for charging A failed or improperly wired rec
401. ty check 7 19 3 AC pOWer eene 7 19 4 diodes tinea etes 7 20 5 DC circuit continuity test 7 21 6 transformer ssesseen 7 23 7 battery state of charge ssss 7 24 8 continuity AC circuit breaker internal 7 27 AC cord and plug eceeeeeeeeeeeeeeeeeeees 7 24 ammeter eterne eek ern dI dedos 7 27 DG COMA 2 iere ener 7 25 telay zie in Tuning ici Lato S 7 27 transformer eerte need 7 26 voltage suppressor ceecee 7 26 transformer installation oreet tette 7 30 remoVal c aine mter EHE 7 30 testing sieves ceive teneis 7 23 7 26 troubleshooting ee 7 12 voltage suppressor testing aiene ee te te deett 7 26 PowerDrive charger external AC circuit breaker charger see circuit breaker 2008 2011 Domestic Battery Charger Maintenance and Service Manual AC cord installation 3 ittis 3 33 remoVal tette tee ie eon ipei co 3 32 testing eere eres 3 24 ammeter installation tentem 3 30 removal eerte 3 30 testing ier pee tei 3 26 batteries battery condition after a charge cycle 3 12 charging batteries that have low voltage 3 34 state of charge test 3 23 battery charger charger features sssssssssesssee 3 2 identification ninin ne a 2 1 installati n 5 2 fiti tetro 3 8 operationis ceti ed eee codices 3 9
402. ual POWERDRIVE 3 MODEL 26580 Test Procedures TEST PROCEDURE 2 ONBOARD COMPUTER See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 1 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to This will ensure that AC power is present 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Insertthe DC cord from the second charger into the receptacle of the vehicle that is not charging properly 4 Ifthe second charger fails in the same manner as the first charger then the vehicle charging circuit is not functioning properly See Troubleshooting on page 7 12 5 Connectthe first charger into another vehicle that is known to be functioning properly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC wall outlet voltage sh
403. uld be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See fol lowing NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 8 7 EN IQ PLUS CHARGER EXTERNAL Checking Battery Condition with an External Charger CHECKING BATTERY CONDITION WITH AN EXTERNAL CHARGER Read DANGER WARNING and CAUTIONS beginning on page 4 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With the IQ Plus vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illu minate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual app
404. ut to 23 in Ib 2 6 N m 2 Connect the DC cord black wire to the other fuse terminal post and install the nut Tighten nut to 23 in Ib 2 6 N m 3 Gently press the fuse assembly into the mounting tab so that the fuse link is visible from the side of the charger 4 Install the charger cover 2008 2011 Domestic Battery Charger Maintenance and Service Manual Page 5 27 ES POWERDRIVE 2 CHARGER EXTERNAL Charger Repairs VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 The voltage suppressor which is incorporated into a wire assembly in the charger protects the onboard com puter by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehicle See also Test Procedure 8 Conti nuity on page 5 20 Voltage Suppressor Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the white wires 3 and 4 from the ammeter Figure 5 20 Page 5 27 Disconnect the white wire from the positive terminal of the rectifier Disconnect the blue red and white wires from the relay o 9 9M Disconnect the DC cord blue wire at the quick disconnect terminal 7 Remove the voltage suppressor and wire assembly from the charger Voltage Suppressor Installation 1 Install in reverse order of removal See following
405. utlet Make sure the charger is wired to the vehicle correctly the vehicle s DC cord red wire should be con nected to the same large solenoid post as the 6 gauge red wire connected to the positive post of bat tery no 1 The DC cord blue wire should be connected to the sense lead fuse The DC cord black wire should be connected to the terminal block located on the vehicle component mounting plate Figure 9 2 Page 9 3 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 4 On rare occasions both diodes may fail as a result of a lightning strike at the charging location 5 Excessive heat due to a loose connection may also cause both fuse links to blow Be sure fuse connec 6 tions are tightened to 22 in Ib 2 5 N m 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 1 2 Disconnect the AC cord from the wall outlet Disconnect the batteries and discharge the controller See Disconnecting The Batteries on page 1 3 Page 9 14 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Test Procedures EN 3 Disconnect the charger DC cord at the three pin connector 8 Figure 9 11 Page 9 16 4 Using
406. val 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 2 Remove the charger cover e Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 9 17 Page 9 22 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink Remove the wire tie that secures the DC cord wire to the secondary coil wire tan Remove the wire tie on the DC cord near the strain relief bushing Disconnect the DC cord blue wire from the control board Figure 9 16 Page 9 22 o NO 2 Using pliers squeeze the strain relief bushing and remove the DC cord Figure 9 16 Page 9 22 DC CORD BLUE WIRE TO DC CORD CONTROL BOARD BLACK WIRE uM RED m AS TO HEATSINK STRAIN RELIEF BUSHING d CORD Figure 9 16 DC Cord Figure 9 17 DC Cord Replacement DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base 2 Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18 in Ib 2 0 N m Figure 9 16 Page 9 22 Page 9 22 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER ONBOARD Charger Repairs EN 3 Attach the blue wire of the new DC cord to the control board Figure 9 16 Page 9 22 4 Attach black wire of the new
407. vidually check all connections and the continuity of the DC cord and ammeter See Test Procedure 8 Conti nuity on page 4 19 Also check the diodes heatsink See Test Procedure 4 Diodes on page 4 14 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 4 14 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 4 19 Remove the DC cord blue wire from the control board and check continuity between the DC cord red black and blue wires Figure 4 4 Page 4 6 There should be no continuity BLACK WIRE BLACK WIRE Figure 4 15 DC Cord Test DS Villager 4 Vehicles Figure 4 16 DC Cord Test Probes Reversed DS Villager 4 Vehicles Page 4 16 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER ONBOARD Test Procedure 5B Precedent Vehicles See General Warning Section 1 Page 1 1 1 Disconnect the AC cord from the wall outlet 2 Connect the batteries See Connecting The Batteries on page 1 4 3 4 Using a continuity tester CC P N 1011273 or multimeter set to 200 ohms connect the test probes to the Disconnect the charger DC cord at the three pin connector Figure 4 3 Page 4 3 charger DC cord black wire and red wire terminals in the three pin connector Figure 4 17 Page 4 18 Note the reading Reverse
408. will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals during a charge cycle with the DC plug still connected if AC power to the charger is interrupted The light will go out when AC power is restored The battery warning light will flash quickly after inserting the DC plug indicating the charger s voltage suppressor has failed closed Page 6 2 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 The Charge Circuit EN THE CHARGE CIRCUIT DS 800 810 AND 850 VEHICLES 4 X 12 VOLT The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 6 2 Page 6 3 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the charger receptacle is connected to the pos itive post of battery no
409. wire from the primary coil tan wire a fF ON Disconnect the AC cord green wire from the charger base Figure 8 19 Page 8 29 6 Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Figure 8 19 Page 8 29 2 Connect the black wire to the AC circuit breaker the white wire to the primary coil and the green wire to the charger base Tighten the screw on the green ground wire terminal to 18 in Ib 2 0 N m 3 Position the strain relief bushing on the AC cord Page 8 28 2008 2011 Domestic Battery Charger Maintenance and Service Manual IQ PLUS CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage E 4 Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 5 Install the charger cover TAN WIRE TO WHITE WIRE PRIMARY COIL A FROM AC CORD GREEN GROUND STRAIN RELIEF BUSHING BLACK WIRE TO CIRCUIT BREAKER e 1 an BLUE WIRE TO DC CORD p TAN WIRE TO PRIMARY COIL AC CIRCUIT VOLTAGE SUPPRESSOR e BREAKER RED WIRE TO HEATSINK Figure 8 19 Charger Relay CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 If battery pack voltage is below 34 volts the charger will not activate The charger relay will
410. y coil tan wire 7 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug 6 The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug 6 Figure 6 22 Page 6 24 The tester should indi cate continuity on only the round pin If any other reading is obtained the AC cord and plug must be replaced Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug 6 The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord and plug must be replaced 10 If the correct readings were obtained install the AC cord See AC Cord Installation on page 6 33 Page 6 24 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE 3 MODEL 26560 Test Procedures E DC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the fuse Figure 6 23 Page 6 27 Disconnect the red wire of the
411. y cord to an AC supply See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug It is for use on a nominal 120 volt 60 hertz circuit The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Mount charger by setting it on a shelf wall mount with keyhole or hang securely from ceiling by the handle Do not hang charger upside down Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Be sure the fuse link is clean and tight not applicable to Precedent vehicles Be sure all wire connections at the receptacle are clean and tight Do
412. y could short circuit and possibly cause a fire 8 After one or two hours disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 See WARNING on page 4 24 9 Disconnect the transformer wire 4 from AC circuit breaker and connect it to the relay Connect the short black wire 3 from the control board to the AC circuit breaker Figure 4 4 Page 4 6 See following WARNING A 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 Page 4 31 POWERDRIVE CHARGER ONBOARD Charging a Battery Pack that has Low Voltage 10 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 34 11 Plug the AC cord into an electrical outlet 12 Allow the charger to continue charging the batteries until the charger shuts off automatically 13 When the charge cycle is complete test the batteries again If the battery pack voltage is above 32 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual TAN I DIODE
413. y secured Connect the black wire ofthe DC cord 5 to the left as viewed from inside the charger post of the amme ter Connect the buss bar 3 from the fuse link to the right post of the ammeter Place flat washers on both sides of the buss bar Thread nuts 4 onto both posts of ammeter until just past finger tight While holding the inside nut tighten the outside nut 4 1 4 turn See following CAUTION CAUTION 6 Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter Install the charger cover 7 Plug the charger into the vehicle and check ammeter for proper operation Figure 3 26 Ammeter Page 3 30 2008 2011 Domestic Battery Charger Maintenance and Service Manual POWERDRIVE CHARGER EXTERNAL Charger Repairs FUSE LINK See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Fuse Link Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove both black secondary coil transformer wires and the buss bar from the back of the fuse link assembly Figure 3 26 Page 3 30 4 Remove screws from the front of the charger and remove the fuse link assembly Fuse Link Installation 1 Place clear plastic cover over fuse assembly and install mounting screws from front of charger face The center branch of the fuse assembly should be in the upper left

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