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Club Car PowerDrive 20310 Maintenance Service Manual
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Club Car PowerDrive 20310 Maintenance Service Manual

Club Car PowerDrive 20310 Maintenance Service Manual

External battery charger
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E UR OPE AN
®
EXTERNAL
BATTERY CHARGER
( M O D E L N O . 2 0 3 1 0 )
2004 MAINTENANCE & SERVICE MANUAL
M a n u a l N o . 1 0 2 3 9 7 6 1 8
E d i t i o n C o d e 0 2 0 4 A 0 0 0 0 0

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Summary of Contents for Club Car PowerDrive 20310

  • Page 1 E UR OPE AN ® EXTERNAL BATTERY CHARGER ( M O D E L N O . 2 0 3 1 0 ) 2004 MAINTENANCE & SERVICE MANUAL M a n u a l N o . 1 0 2 3 9 7 6 1 8 E d i t i o n C o d e 0 2 0 4 A 0 0 0 0 0...
  • 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 – EUROPEAN 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 ∆ 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.
  • Page 9 SAFETY General Warning ∆ WARNING • Carryall Electric Industrial Trucks: After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard. When the buzzer stops sounding, the controller is discharged.
  • Page 10 SAFETY General Warning Place Tow/Run Remove negative (–) FRONT Place Tow/Run Switch in TOW. cable first. OF VEHICLE switch in TOW. PLACE TOW/RUN SWITCH IN THE TOW POSITION BEFORE PLACE TOW/RUN SWITCH DISCONNECTING OR Remove negative IN THE TOW POSITION BEFORE CONNECTING BATTERY CABLES DISCONNECTING OR cable first.
  • 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 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.
  • Page 14 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.
  • Page 15 EUROPEAN POWERDRIVE BATTERY CHARGER The Charge Circuit 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–...
  • Page 16 EUROPEAN POWERDRIVE BATTERY CHARGER The Charge Circuit ONBOARD SOLID STATE SPEED CONTROLLER COMPUTER FUSE LINK #10 BLACK B– B– TERMINAL #6 BLACK CHARGER RECEPTACLE #10 BLACK #10 BLACK #18 GRAY #18 GRAY #10 RED SENSE LEAD FUSE Figure 3-3 Charge Circuit – Turf 2, Carryall 2, Carryall 6, Villager 6, Villager 8, and TransPorter Vehicles SOLID STATE ONBOARD SPEED CONTROLLER...
  • Page 17 EUROPEAN POWERDRIVE BATTERY CHARGER The Charge Circuit SOLID STATE ONBOARD SPEED CONTROLLER COMPUTER FUSE LINK CHARGER RECEPTACLE #6 BLACK #10 BLACK #10 BLACK #18 GRAY #18 GRAY #10 BLACK SENSE LEAD FUSE #10 RED BATT – FRONT OF VEHICLE Figure 3-5 Charge Circuit – Carryall 1 Industrial Truck SOLID STATE ONBOARD SPEED CONTROLLER...
  • Page 18 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Installation and Operation FRONT CHARGER TO SOLENOID OF VEHICLE RECEPTACLE BATTERY BANK SINGLE POSITION CONNECTOR ONBOARD COMPUTER SOLID STATE SPEED CONTROLLER Figure 3-7 Charge Circuit and Battery Configuration – Precedent Vehicles CHARGER INSTALLATION AND OPERATION See General Warning, Section 1, Page 1-1.
  • Page 19 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Installation and Operation • The battery charger DC plug must be pulled slowly from the receptacle (Figure 3-8, Page 3-7). Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode (Figure 3-9, Page 3-7).
  • Page 20 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. 220 V...
  • Page 21 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Installation and Operation CHARGING BATTERIES ∆ 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). •...
  • 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 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Installation and Operation 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 ®...
  • Page 24 EUROPEAN POWERDRIVE BATTERY CHARGER 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.
  • Page 25 EUROPEAN POWERDRIVE BATTERY CHARGER Troubleshooting Use the following Troubleshooting Guide for troubleshooting European PowerDrive external battery chargers (model numbers 20310-11 and 20310-18). The Troubleshooting Guide encompasses the entire battery charg- ing circuit. Test procedures specified in the Troubleshooting Guide can be found on the following pages. EUROPEAN POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...
  • Page 26 EUROPEAN POWERDRIVE BATTERY CHARGER Troubleshooting EUROPEAN POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Both charger fuse links blow or Battery is wired in reverse polarity Check vehicle wiring receptacle fuse link blows DC cord is wired in reverse polarity Check battery charger wiring Test Procedure 4B –...
  • Page 27 EUROPEAN POWERDRIVE BATTERY CHARGER Troubleshooting Figure 3-12 European PowerDrive Battery Charger 2004 European PowerDrive Battery Charger Maintenance and Service Manual Page 3-15...
  • Page 28 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures TEST PROCEDURES See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1. 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.
  • Page 29 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures ∆ WARNING • Do not bypass the sense lead fuse. CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER SENSE LEAD FUSE Figure 3-13 Receptacle Wire Connections 3.3. Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 Ω (ohms). The resistance should be less than 2 Ω...
  • Page 30 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 1 – Battery Voltage and DC Plug and Receptacle, Continued: Precedent 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.
  • Page 31 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 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. NOTE: Leave one end of the AC cord connected to the battery charger, but disconnect the AC plug from the incoming AC outlet.
  • Page 32 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 3 – AC Power and Continuity Test of AC Circuit, Continued: 6. If the circuit is not complete, check the wiring of the AC cord (16 or 17), AC charger receptacle (14), trans- former primary coil wires (21), internal AC circuit breakers (13), voltage selector switch (9), and jumper wires (Figure 3-12, Page 3-15).
  • Page 33 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 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 34 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 5 – Charger DC Circuit Continuity Test, Continued: POSITIVE PIN POSITIVE PIN PULL HERE PULL HERE PULL HERE PULL HERE PULL HERE PULL HERE NEGATIVE PIN NEGATIVE PIN Figure 3-19 DC Plug Test Figure 3-20 DC Plug Test –...
  • Page 35 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures DC CORD DIODES WITH HEATSINK BLUE LIMITER BLACK BLACK BLACK SECONDARY COIL VOLTAGE BLACK SUPPRESSOR FUSE AMMETER PRIMARY COIL RELAY AC CORD SOCKET BLACK CAP. BLACK GRN/YEL RELAY BYPASS RELAY BYPASS JUMPER WIRE JUMPER WIRE CASE GROUND BLACK...
  • Page 36 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 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 reconnect it.
  • Page 37 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 4. Disconnect black wire from charger relay terminal 4 (4). 5. Disconnect black wire from charger relay terminal 8 (8). 6. Using a multimeter, set for 200 Ω (ohms), place the red (+) probe on the terminal at the end of the black wire removed from relay terminal 4 (4) (Figure 3-22, Page 3-24).
  • Page 38 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures AC Charger Receptacle 1. Disconnect the AC cord from the AC receptacle (on front of battery charger) and the incoming AC outlet. Disconnect the battery charger from the vehicle. 2. Disconnect black wire from charger relay terminal 4 (4) (Figure 3-24, Page 3-26 and Figure 3-11, Page 3-11).
  • Page 39 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 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 (17) of the DC cord from the ammeter (Figure 3-25, Page 3-27).
  • Page 40 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Transformer The PowerDrive battery charger transformer has two sets of coils: a primary coil and a secondary coil (Figure 3-11, Page 3-11). Primary Coil 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. 2.
  • Page 41 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Voltage Suppressor – Failed Closed 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. 2. Remove the charger cover. ç 3. 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.
  • Page 42 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs 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.
  • Page 43 EUROPEAN 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).
  • Page 44 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs Heatsink Installation, Continued: 4. Connect the other secondary coil transformer wire (tan) to the top terminal post of the heatsink. Tighten nut to 18 in-lb (2.0 N·m). 5. Install the charger cover and check charger for proper operation. TRANSFORMER See General Warning, Section 1, Page 1-1.
  • Page 45 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs AMMETER See General Warning, Section 1, Page 1-1. See additional 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 3-30.
  • Page 46 EUROPEAN POWERDRIVE BATTERY CHARGER 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. See WARNING on page 3-30.
  • Page 47 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs Voltage Suppressor Installation 1. Place the white fiberglass sleeve over the red wire that connects to the heatsink. 2. 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).
  • Page 48 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs CHARGER AC CIRCUIT BREAKERS 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. See WARNING on page 3-30.
  • Page 49 EUROPEAN POWERDRIVE BATTERY CHARGER 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.
  • Page 50 EUROPEAN POWERDRIVE BATTERY CHARGER Charging a Battery Pack that has Low Voltage Charging a Battery Pack that has Low Voltage, Continued: ∆ WARNING • The relay wiring must be properly connected prior to placing the charger back into normal service. Failure to remove the jumper wire and properly connect the relay wiring could result in property damage, severe personal injury, or death.
  • Page 51 INDEX AC charger receptacle electrical system installation ............3-36 charge circuit ............. 3-3 removal ............3-36 testing ............ 3-24, 3-26 AC circuit breaker, charger fuse link see circuit breaker installation ............3-34 AC cord removal ............3-34 testing ............ 3-24, 3-25 ammeter installation ............
  • Page 52 INDEX 8 – continuity AC charger receptacle ........ 3-26 AC cord ............3-25 AC cord and AC charger receptacle ... 3-24 ammeter ............3-30 circuit breaker ..........3-30 DC cord ............3-27 limiter ............3-29 relay ............3-29 transformer ..........3-28 voltage suppressor ........
  • Page 53 2004 European PowerDrive Battery Charger Maintenance and Service Manual...
  • Page 56 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...