Club Car PowerDrive 18780 Maintenance Service Manual

External battery charger

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EXPO R T

XPO

EXTERNAL

BATTERY CHARGE

( M O D E

M O D E L N O . 1 8 7 8 0

N O . 1 8 7 8 0 0 )

N O . 1 8

2001/2002 MAINTENANCE & SERVICE MANUAL

M a n u a l N o . 1 0 2 2 6 0 2 0 2

R T

AL L

HARGER

HAR

RGE

8 7 8 0

E d i t i o n C o d e 1 1 0 1 A 0 0 0 0 0

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Summary of Contents for Club Car PowerDrive 18780

Page 1 EXPO R T ® EXTERNAL AL L BATTERY CHARGE HARGER ( M O D E ( M O D E M O D E L N O . 1 8 7 8 0 N O . 1 8 N O . 1 8 7 8 0 0 ) 8 7 8 0 2001/2002 MAINTENANCE &...
Page 3 Car factory-trained technician. It is the policy of Club Car, Inc. 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- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support.
Page 4 ∆ WARNING • 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.
Page 5 CONTENTS SECTION 1 – SAFETY General Warning ..........................SECTION 2 – CHARGER IDENTIFICATION AND SPECIFICATIONS General Information .......................... Battery Charger Specifications ......................Battery Charger Identification ......................SECTION 3 – EXPORT POWERDRIVE BATTERY CHARGER General Information .......................... PowerDrive Charger Features ...................... Battery Warning Light ........................
Page 7 SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles 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.
Page 8 SAFETY General Warning • 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.
Page 9 SAFETY General Warning • 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. •...
Page 11 SPECIFICATIONS GENERAL INFORMATION There are several different Club Car 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. See Battery Charger Identiﬁcation on page 2-2.
Page 12 The battery charger can be identiﬁed by the model number printed on the side panel, top panel, or front panel of the charger. Do not attempt to service a battery charger that cannot be properly identiﬁed. If a charger can- not be identiﬁed, contact your local Club Car dealer or distributor. Page 2-2...
Page 13 SECTION 3 – EXPORT POWERDRIVE BATTERY CHARGER ∆ 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 space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 14 EXPORT POWERDRIVE BATTERY CHARGER • 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. •...
Page 15 1018780-11 and 1018780-18). Depending on the geographic region, the charger provided with your vehicle may be a different model. Do not attempt to service a battery charger that has not been properly iden- tiﬁed. If a charger cannot be properly identiﬁed, contact your local Club Car dealer or distributor. 220 V...
Page 16 The Charge Circuit BATTERY WARNING LIGHT The 48-volt Club Car electric vehicle features a dash-mounted battery warning light (above the steering col- umn) which, when the vehicle is in operation, indicates low battery voltage or, when the vehicle is being charged, indicates a charging problem.
Page 17 EXPORT POWERDRIVE BATTERY CHARGER The Charge Circuit SOLID STATE SPEED CONTROLLER (SPEED CONTROLLER FOR IQ SYSTEM ONBOARD AND POWERDRIVE PLUS WILL HAVE COMPUTER DIFFERENT APPEARANCE) FUSE LINK No.10 BLACK B– B– TERMINAL No. 6 BLACK CHARGER RECEPTACLE No. 10 BLACK No.
Page 18 EXPORT POWERDRIVE BATTERY CHARGER The Charge Circuit SOLID STATE ONBOARD SPEED CONTROLLER COMPUTER FUSE LINK No.10 BLACK No.6 BLACK CHARGER RECEPTACLE No.10 BLACK B– No.10 BLACK TERMINAL No.18 GRAY No.18 GRAY SENSE LEAD FUSE No.10 RED Figure 3-5 Charge Circuit – DS Limo electric SOLID STATE ONBOARD SPEED CONTROLLER...
Page 19 EXPORT POWERDRIVE BATTERY CHARGER Charger Installation and Operation SOLID STATE ONBOARD SPEED CONTROLLER COMPUTER FUSE LINK CHARGER No.6 BLACK RECEPTACLE No.10 BLACK No.10 BLACK No.18 GRAY No.18 GRAY No.10 BLACK SENSE LEAD FUSE No.10 RED BATT – FUSE Figure 3-7 Charge Circuit – Carryall 2 and Carryall 6 Industrial Trucks CHARGER INSTALLATION AND OPERATION Read DANGER and WARNING on page 3-1.
Page 20 • 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. With charger DC cord disconnected, connect the power supply cord to an AC supply within the acceptable voltage range.
Page 21 EXPORT POWERDRIVE BATTERY CHARGER Charger Installation and Operation 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.
Page 22 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.
Page 23 EXPORT POWERDRIVE BATTERY CHARGER Checking Battery Condition 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 90% charged, the battery warning light will illuminate inter- mittently.
Page 24 EXPORT POWERDRIVE BATTERY CHARGER Checking Battery Condition DIODE AND HEATSINK PRIMARY COIL SECONDARY COIL TRANSFORMER AMMETER FUSE AND LENS ASSEMBLY RELAY DC CORD Figure 3-11 PowerDrive Export Battery Charger Page 3-12 2001/2002 Export PowerDrive Battery Charger Maintenance and Service Manual...
Page 25 EXPORT POWERDRIVE BATTERY CHARGER Troubleshooting TROUBLESHOOTING Read DANGER and WARNING on page 3-1. ∆ 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 26 EXPORT POWERDRIVE BATTERY CHARGER Troubleshooting EXPORT POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay closes and transformer hums but Test Procedure 5 – Charger DC Circuit Blown charger fuse ammeter does not move Continuity Test on page 3-20 Test Procedure 4B –...
Page 27 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures EXPORT POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Battery warning light illuminates for Test Procedure 3 – AC Power and AC power interrupted ten seconds, at four second intervals Continuity Test of AC Circuit on page 3-17 (with DC charger cord plugged in) Test Procedure 2 –...
Page 28 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 1 – Battery Voltage and DC Plug and Receptacle, Continued: • DS Limo electric vehicles: Verify that the 10-gauge red wire from the charger receptacle is connected to the same large post of the solenoid as the 4-gauge red wire that connects to the positive (+) post of battery no.
Page 29 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures Place multimeter Place multimeter red (+) probe here. red (+) probe here. FRONT OF VEHICLE Place multimeter black (–) probe here. Place multimeter black (–) probe here. Refer to the appropriate battery configuration. (Rubber boots removed for clarity) Figure 3-13 PowerDrive, PowerDrive Plus, and IQ System Battery Conﬁguration TEST PROCEDURE 2 –...
Page 30 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 3 – AC Power and Continuity Test of AC Circuit, Continued: 4. With a multimeter set to 500 volts AC, check incoming AC voltage. Insert multimeter test probes into AC wall outlet; voltage should be within the range speciﬁed in the following chart. If proper voltage is not present and the voltage selector switch is set for the correct voltage for your area, have building wiring checked by a licensed electrical contractor.
Page 31 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures 6. If the circuit is not complete, check the wiring of the AC cord (16), transformer primary coil wires (21), internal AC circuit breakers (13), voltage selector switch (9), and jumper wires (Figure 3-11, Page 3-12). 7.
Page 32 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 4 – Single Diode Failure, Continued: 6. On rare occasions, a single fuse link may blow due to excessive heat. This can be caused by a loose internal fuse connection. Check all three fuse connections inside the charger to be sure they are clean and tight.
Page 33 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures 4. If the circuit does not show continuity in either direction and the charger fuse is not blown, individually check all connections and the continuity of the DC cord and ammeter. See Test Procedure 8 – Conti- nuity on page 3-23.
Page 34 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 6 – Transformer, Continued: 4.3. Use a jumper wire with alligator clips to connect the black wire from relay terminal 9 to the brown wire from relay terminal 6 (Figure 3-19, Page 3-22). 4.4.
Page 35 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures 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. 9. 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 3-19, Page 3-22).
Page 36 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 8 – Continuity, Continued: 8. Place red (+) probe on the blue wire and check for continuity on both ﬂat blades and on the round 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 plug must be replaced.
Page 37 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures DC CORD BLUE WIRE TO RED WIRE ASSEMBLY AT RELAY DC CORD BLACK WIRE TO AMMETER DC CORD RED WIRE TO HEAT SINK Figure 3-21 DC Cord Transformer The PowerDrive battery charger transformer has two sets of coils: a primary coil and a secondary coil (Figure 3-10, Page 3-10).
Page 38 EXPORT POWERDRIVE BATTERY CHARGER Test Procedures 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 lead from the upper terminal of the heatsink (Figure 3-10, Page 3-10).
Page 39 EXPORT POWERDRIVE BATTERY CHARGER Charger Repairs 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 probes on the two terminals of the AC circuit breaker. The tester should indicate continuity.
Page 40 EXPORT POWERDRIVE BATTERY CHARGER 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-lb (2.0 N·m) (Figure 3-21, Page 3-25).
Page 41 EXPORT POWERDRIVE BATTERY CHARGER Charger Repairs TRANSFORMER Read DANGER and WARNING on page 3-1. Transformer Removal 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. See WARNING on page 3-27. 2. Remove the charger cover. 3.
Page 42 EXPORT POWERDRIVE BATTERY CHARGER Charger Repairs AMMETER Read DANGER and WARNING on page 3-1. Ammeter Removal 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. See WARNING on page 3-27. 2. Remove the charger cover. 3.
Page 43 EXPORT POWERDRIVE BATTERY CHARGER Charger Repairs FUSE LINK Read DANGER and WARNING on page 3-1. Fuse Link Removal 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. See WARNING on page 3-27. 2. Remove the charger cover. 3.
Page 44 EXPORT POWERDRIVE BATTERY CHARGER Charger Repairs 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-lb (2.0 N·m). CHARGER RELAY Read DANGER and WARNING on page 3-1. Charger Relay Removal 1.
Page 45 EXPORT POWERDRIVE BATTERY CHARGER Charging a Battery Pack that has Low Voltage CHARGER AC CIRCUIT BREAKERS Read DANGER and WARNING on page 3-1. AC Circuit Breaker Removal 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. See WARNING on page 3-27.
Page 46 EXPORT POWERDRIVE BATTERY CHARGER Charging a Battery Pack that has Low Voltage Charging a Battery Pack that has Low Voltage, Continued: ∆ WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 3-10, Page 3-10). •...
Page 47 EXPORT POWERDRIVE BATTERY CHARGER Charging a Battery Pack that has Low Voltage 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.
Page 49 INDEX AC circuit breaker, charger electrical system see circuit breaker charge circuit ............. 3-4 AC cord installation ............3-33 removal ............3-33 fuse link testing ............. 3-23 installation ............3-31 ammeter removal ............3-31 installation ............3-30 removal ............3-30 testing .............
Page 50 INDEX 8 – continuity AC circuit breaker ........3-27 AC cord ............3-23 ammeter ............3-26 DC cord ............3-24 relay ............3-26 transformer ..........3-25 voltage suppressor ........3-26 transformer installation ............3-29 removal ............3-29 testing .............3-21, 3-25 troubleshooting ..........
Page 51 2001/2002 Export PowerDrive Battery Charger Maintenance and Service Manual...
Page 54 Club Car, Inc. www.clubcar.com P . Box 204658 Phone 1.706.863.3000 Augusta, GA 30917- 7- 7 4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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Powerdrive 1018780-11 Powerdrive 1018780-18