Club Car 2005 Domestic Maintenance And Service Manual
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Club Car 2005 Domestic Maintenance And Service Manual

Club Car 2005 Domestic Maintenance And Service Manual

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D OM ES T IC
®
&
B AT T E RY CH A RG E R S
2005 MAINTENANCE & SERVICE MANUAL
E d i t i o n C o d e 1 2 0 4 A 0 0 0 0 0
M a n u a l N o . 1 0 2 6 8 0 4 1 4

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Summary of Contents for Club Car 2005 Domestic

  • Page 1 D OM ES T IC ® & B AT T E RY CH A RG E R S 2005 MAINTENANCE & SERVICE MANUAL E d i t i o n C o d e 1 2 0 4 A 0 0 0 0 0 M a n u a l N o .
  • 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 ý 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: Table Of Contents

    3-27 Voltage Suppressor ........................3-27 Charger Relay ..........................3-28 Charger AC Circuit Breaker ......................3-28 Charger AC Cord .......................... 3-28 Charging a Battery Pack that has Low Voltage ................3-29 2005 Domestic Battery Charger Maintenance and Service Manual Page iii...
  • Page 6 DC Cord and Plug Inspection ....................... Checking Battery Condition After a charge Cycle ................Start Charge Cycle ........................Troubleshooting ..........................Test Procedures ..........................5-12 Index of Test Procedures ......................5-12 Page iv 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 7 6-28 Charger Relay ..........................6-29 Charger AC Circuit Breaker ......................6-29 Charger AC Cord .......................... 6-29 Charging a Battery Pack that has Low Voltage ................6-30 SECTION i – INDEX 2005 Domestic Battery Charger Maintenance and Service Manual Page v...

  • Page 9: Section 1 - Safety

    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 10 • 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. WARNING CONTINUED ON NEXT PAGE... Page 1-2 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 11 Remove negative connecting battery cables. IN THE TOW POSITION BEFORE DISCONNECTING OR cable first. CONNECTING BATTERY CABLES Figure 1-2 DS IQ System Battery Configuration Figure 1-3 Precedent IQ System Battery Configuration 2005 Domestic Battery Charger Maintenance and Service Manual Page 1-3...

  • Page 13: Section 2 - Charger Identification And Specifications

    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 2-4.
  • Page 14 AC input AC voltage: 105-128 VAC (acceptable range) • • • Frequency: 60 Hz. • • • Power consumption Max. AC current (amps) 10.71 10.71 10.71 Specifications continued on next page... Page 2-2 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 15 (204.5 cm) (328.9 cm) (412.8 cm) Weight 37 lb (16.8 kg) 37.7 lb (17.1 kg) 38.2 lb (17.3 kg) Mounting Configuration Mounting: Onboard (secured to the vehicle) • • • 2005 Domestic Battery Charger Maintenance and Service Manual Page 2-3...

  • Page 16: Battery Charger Identification

    Do not attempt to service a battery charger that cannot be properly identified. If a charger cannot be identified, contact your local Club Car dealer or distributor. BATTERY CHARGER NAME...

  • Page 17: Section 3 - Powerdrive Charger (External)

    17930-11, 17930-18, and 17930-19). 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.

  • Page 18: Powerdrive External Charger Features

    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 3-2 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 19: The Charge Circuit

    #18 GRAY #10 RED TO SOLENOID SENSE LEAD FUSE BLACK TO NEGATIVE TERMINAL Figure 3-2 Charge Circuit and Battery Configuration – DS, Turf 1, Carryall 1 and DS Villager 4 Vehicles 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-3...
  • Page 20 Figure 3-3 Charge Circuit and Battery Configuration – Turf 2, Carryall 2 and Villager 6 and 8 Vehicles FRONT CHARGER TO SOLENOID OF VEHICLE RECEPTACLE BATTERY BANK SINGLE POSITION CONNECTOR ONBOARD COMPUTER SOLID STATE SPEED CONTROLLER Figure 3-4 Charge Circuit and Battery Configuration – Precedent Vehicles Page 3-4 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 21: Charger Installation And Operation

    • 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-5...

  • Page 22: Ac Power Connection

    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. Page 3-6 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 23 (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;...

  • Page 24: Testing Charger Operation

    See also DC Cord Removal on page 3-23. See following NOTE. NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately. Page 3-8 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 25: Checking Battery Condition After A Charge Cycle

    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.
  • Page 26 3-20 Single charger fuse link blows Test Procedure 4A – Single Diode Failure Diode failed on page 3-16 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page... Page 3-10 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 27 10 second intervals for Onboard computer malfunction page 3-15 Precedent vehicles) See Section 13 – Batteries in the Battery or batteries need to be replaced appropriate maintenance and service manual 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-11...

  • Page 28: Test Procedures

    2. Onboard Computer 3. AC Power and Continuity Test of AC Circuit 4. Diodes 5. Charger DC Circuit Continuity Test 6. Transformer 7. Battery State of Charge Test 8. Continuity Page 3-12 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 29 Figure 3-9 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-13...
  • Page 30 See Charging a Battery Pack that has Low Voltage on page 3-29. Place multimeter black (–) probe here. FRONT OF VEHICLE Place multimeter red (+) probe here. Figure 3-11 Precedent Battery Configuration Page 3-14 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 31 (4) from the relay. Connect the tan wire (4) to the AC circuit breaker (Figure 3-17, Page 3-19). 5.3. With relay bypassed, there should be continuity across the AC cord blades (Figure 3-12, Page 3-15). Figure 3-12 AC Cord Test 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-15...
  • Page 32 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-lb (2.5 N·m). Page 3-16 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 33 4. Excessive heat due to a loose connection may also cause both fuse links to blow. Be sure fuse connec- tions are tightened to 22 in-lb (2.5 N·m). 5. Ensure that the charger and vehicle are wired properly and all connections are clean and tight. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-17...
  • Page 34 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. 2. Remove the charger cover. 3. Disconnect transformer secondary coil wires (1 and 5) from the heatsink (Figure 3-17, Page 3-19). Page 3-18 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 35 • 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-19...
  • Page 36 AC cord and plug must be replaced. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V (OHM) SETTING Figure 3-18 AC Cord and Plug Continuity Test Page 3-20 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 37 If tester does not indicate continuity on both secondary coil wires, replace transformer. Ensure that the fuse is intact and not blown. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-21...
  • Page 38 4. 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 3-22 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 39: Charger Repairs

    DC CORD TO RED WIRE ASSEMBLY BLACK WIRE AT RELAY TO AMMETER DC CORD RED WIRE TO HEATSINK STRAIN RELIEF BUSHING Figure 3-19 DC Cord Figure 3-20 DC Cord Replacement 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-23...

  • Page 40: Heatsink

    Tighten nut to 18 in-lb (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-lb (2.0 N·m). Page 3-24 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 41: Transformer

    • 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. 9. Install the charger cover and check charger for proper operation. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-25...

  • Page 42: Ammeter

    • 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. 7. Plug the charger into the vehicle and check ammeter for proper operation. Figure 3-21 Ammeter Page 3-26 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 43: Fuse Link

    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 3-22, Page 3-29). 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-27...

  • Page 44: Charger Relay

    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-lb (2.0 N·m). 3. Position the strain relief bushing on the AC cord. Page 3-28 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 45: Charging A Battery Pack That Has Low Voltage

    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 3-23, Page 3-30). See following DANGER. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-29...
  • Page 46 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. Page 3-30 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 47: 2005 Domestic Battery Charger Maintenance And Service Manual

    See Section 11 – Electrical System and Testing in the appropriate maintenance and service manual. 2005 Domestic Battery Charger Maintenance and Service Manual Page 3-31...

  • Page 49: Section 4 - Carryall 6 And Transporter Powerdrive Charger (Onboard)

    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 Carryall 6 and TransPorter vehicles, contact your local Club Car dealer or distributor.

  • Page 50: Powerdrive Onboard Charger Features

    • 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 CHARGE CIRCUIT For Carryall 6 and TransPorter vehicles with onboard chargers, the charge circuit consists of the following: •...

  • Page 51: Charger Operation

    • 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. WARNING CONTINUED ON NEXT PAGE... 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-3...
  • Page 52 This test will be repeated at one hour and two hours into the charge cycle. See following CAUTION and NOTE. Page 4-4 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 53 (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;...

  • Page 54: Checking Battery Condition

    See Onboard Charger Removal on page 4-30. Use the following Troubleshooting Guide for troubleshooting PowerDrive onboard battery chargers (model numbers 17935-10, 17935-20, and 17935-30) installed in Carryall 6 and TransPorter vehicles. The Trouble- Page 4-6 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 55 4-16 Single charger fuse link blows Test Procedure 4A – Single Diode Failure Diode failed on page 4-12 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page... 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-7...
  • Page 56 See Section 13 – Batteries in the Battery or batteries need to be replaced appropriate maintenance and service manual Batteries are getting close to full Recharge batteries as soon as possible discharge capacity Page 4-8 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 57: Test Procedures

    • 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-9...
  • Page 58 ý 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 4-10 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 59 6. If the circuit is not complete, check the wiring of the AC cord, AC cord reel, transformer primary coil wires, and internal AC circuit breaker (Figure 4-13, Page 4-15). 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-11...
  • Page 60 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 4-9, Page 4-13). Page 4-12 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 61 DC cord is connected to the vehicle, whether or not the AC cord is plugged into an outlet. 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-13...
  • Page 62 (Figure 4-3, Page 4-5). There should be no continuity. BLUE WIRE BLUE WIRE CORD CORD RED WIRE RED WIRE BLACK WIRE BLACK WIRE Figure 4-11 DC Cord Test Figure 4-12 DC Cord Test – Probes Reversed Page 4-14 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 63 No. 10 RING TERMINAL BLACK BLACK BLACK BLUE FUSE AMMETER CONTROL BOARD RELAY AC CIRCUIT BREAKER BLACK BLACK GREEN CASE WHITE GROUND AC CORD Figure 4-13 Transformer Test Wiring Diagram 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-15...
  • Page 64 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 4-30. 3. Remove the charger cover. Page 4-16 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 65 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 4-30. 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-17...
  • Page 66 6. Disconnect the green wire (2) from charger case and position it so it does not touch any metal part of the charger (Figure 4-16, Page 4-18). WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 4-16 Short AC Cord Test Page 4-18 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 67 If any other reading is obtained, the cord reel must be replaced. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 4-17 Retractable Cord Reel Test 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-19...
  • Page 68 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 4-30. 2. Remove the charger cover. Page 4-20 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 69: Charger Repairs

    • 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 4-30. 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-21...

  • Page 70: Dc Cord

    • 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. Page 4-22 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 71: Heatsink

    5. Remove the wire tie that secures the DC cord wire to the secondary coil wire (tan). 6. Disconnect the two tan secondary coil transformer wires from the heatsink (Figure 4-3, Page 4-5). 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-23...

  • Page 72: Ammeter

    3. Disconnect the black wire from the DC cord (5), and the buss bar (3) from the ammeter (Figure 4-20, Page 4-25). 4. Remove the two nuts (2) that secure the ammeter to the charger face. 5. Remove the ammeter from the face of the charger. Page 4-24 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 73: Fuse Link

    3. Remove both black secondary coil transformer wires and the buss bar from the back of the fuse link assembly (Figure 4-20, Page 4-25). 4. Remove screws from the front of the charger and remove the fuse link assembly. 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-25...

  • Page 74: Charger Relay

    BLACK WIRE TO PRIMARY COIL AC CURCUIT BREAKER CHARGER RELAY AC CORD STRAIN RELIEF BUSHING WHITE WIRE FROM AC CORD BLACK WIRE TO GREEN GROUND CIRCUIT BREAKER WIRE Figure 4-21 Charger Relay Page 4-26 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 75: Charger Ac Circuit Breaker

    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 4-31. 6. Check charger for proper operation. 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-27...

  • Page 76: Retractable Ac Cord Reel

    6. Plug the AC cord into an electrical outlet. 7. The charger should activate and begin to charge the batteries. Allow the charger to operate for one or two hours. See following WARNING. Page 4-28 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 77 No. 10 RING TERMINAL BLACK BLACK BLACK BLUE FUSE AMMETER CONTROL BOARD RELAY AC CIRCUIT BREAKER BLACK BLACK GREEN CASE WHITE GROUND AC CORD Figure 4-22 PowerDrive Onboard Charger Wiring Diagram (Relay Bypassed) 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-29...

  • Page 78: Onboard Charger Removal And Installation

    7. Cut wire tie that secures DC cord to wiring harness. 8. Remove four screws from the AC cord bezel and remove cord from bezel. 9. Lift charger and reel assembly from vehicle. Page 4-30 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 79 1. Installation is reverse of removal. Tighten four screws connecting AC cord bezel to frame to 12 in-lb (2.5 N·m). 2. Connect battery cables, positive (+) cable first, and tighten to 110 in-lb (12.4 N·m). 2005 Domestic Battery Charger Maintenance and Service Manual Page 4-31...

  • Page 81: Section 5 - Powerdrive 2 Charger (External)

    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.

  • Page 82: Powerdrive 2 Battery Charger Features

    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 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 83: The Charge Circuit

    RECEPTACLE #10 BLACK #10 BLACK #18 GRAY #18 GRAY #10 RED To Solenoid SENSE LEAD FUSE BLACK TO NEGATIVE TERMINAL Figure 5-2 Charge Circuit and Battery Configuration – DS Vehicles 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-3...

  • Page 84: Charger Installation And Operation

    • 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 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 85 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 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-5...

  • Page 86: Ac Power Connection

    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 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 87: Testing Charger Operation

    (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;...

  • Page 88: Dc Cord And Plug Inspection

    See also DC Cord Removal on page 5-24. See following NOTE. NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately. Page 5-8 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 89: Checking Battery Condition After A Charge Cycle

    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.
  • Page 90 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... Page 5-10 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 91 10 second intervals for Onboard computer malfunction page 5-15 Precedent vehicles) See Section 13 – Batteries in the Battery or batteries need to be replaced appropriate maintenance and service manual 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-11...

  • Page 92: Test Procedures

    2. Onboard Computer 3. AC Power and Continuity Test of AC Circuit 4. Rectifier 5. Charger DC Circuit Continuity Test 6. Transformer 7. Battery State of Charge Test 8. Continuity Page 5-12 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 93 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-13...
  • Page 94 See Charging a Battery Pack that has Low Voltage on page 5-30. Place multimeter black (–) probe here. FRONT OF VEHICLE Place multimeter red (+) probe here. Figure 5-10 Precedent Battery Configuration Page 5-14 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 95 (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 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-15...
  • Page 96 750V ç ç DIODE ( ) SETTING DIODE ( ) SETTING (AC) (AC) – – (AC) (AC) RECTIFIER RECTIFIER Figure 5-12 Rectifier Test Figure 5-13 Rectifier Test – Probes Reversed Page 5-16 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 97 POSITIVE PIN WAVETEK 1000 PULL HERE PULL HERE PULL HERE PULL HERE 2000 200k 200nA 1000 --- FUSED 750V ç NEGATIVE PIN DIODE ( ) SETTING Figure 5-14 DC Plug Test 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-17...
  • Page 98 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 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 99 BLACK (AC) AC INPUT PLUG GREEN BLACK BLACK (DISCONNECTED FROM RELAY CASE – (AC) AND CONNECTED TO BREAKER) AC CORD GROUND RECTIFIER WHITE BLACK Figure 5-16 Transformer Test Wiring Diagram 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-19...
  • Page 100 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). WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 5-17 AC Cord and Plug Continuity Test Page 5-20 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 101 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-21...
  • Page 102 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. Page 5-22 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 103: Charger Repairs

    (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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-23...

  • Page 104: Dc Cord

    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-lb (1.2 N·m). Page 5-24 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 105: Rectifier

    • 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-25...

  • Page 106: Transformer

    • 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. Page 5-26 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 107: Ammeter

    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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-27...

  • Page 108: Fuse Link

    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. Page 5-28 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 109: Charger Relay

    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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-29...

  • Page 110: Charging A Battery Pack That Has Low Voltage

    ý 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 5-30 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 111 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 5-31...
  • Page 112 See Section 11 – Electrical System and Testing in the appropriate maintenance and service manual. Page 5-32 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 113: Section 6 - Ge Powerdrive Charger (External)

    The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter- ies. Figure 6-1 GE PowerDrive Battery Charger 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-1...

  • Page 114: Ge Powerdrive Battery Charger Features

    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 6-2 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 115: The Charge Circuit

    RECEPTACLE #10 BLACK #10 BLACK #18 GRAY #18 GRAY #10 RED To Solenoid SENSE LEAD FUSE BLACK TO NEGATIVE TERMINAL Figure 6-2 Charge Circuit and Battery Configuration – DS Vehicles 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-3...

  • Page 116: Charger Installation And Operation

    • 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 6-4 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 117 Note: Appearance of receptacle Note: Appearance of may vary depending on vehicle. receptacle may vary depending on vehicle. Figure 6-4 Charger Receptacle Figure 6-5 Incorrect DC Plug Removal 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-5...

  • Page 118: Ac Power Connection

    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 6-6 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 119: Testing Charger Operation

    (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;...

  • Page 120: Dc Cord And Plug Inspection

    See also DC Cord Removal on page 6-24. See following NOTE. NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately. Page 6-8 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 121: Checking Battery Condition After A Charge Cycle

    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.
  • Page 122 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... Page 6-10 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 123 10 second intervals for Onboard computer malfunction page 6-15 Precedent vehicles) See Section 13 – Batteries in the Battery or batteries need to be replaced appropriate maintenance and service manual 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-11...

  • Page 124: Test Procedures

    2. Onboard Computer 3. AC Power and Continuity Test of AC Circuit 4. Rectifier 5. Charger DC Circuit Continuity Test 6. Transformer 7. Battery State of Charge Test 8. Continuity Page 6-12 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 125 Figure 6-8 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-13...
  • Page 126 See Charging a Battery Pack that has Low Voltage on page 6-30. Place multimeter black (–) probe here. FRONT OF VEHICLE Place multimeter red (+) probe here. Figure 6-10 Precedent Battery Configuration Page 6-14 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 127 (4) from the relay. Connect the brown wire (4) to the AC circuit breaker (Figure 6-16, Page 6-19). 5.3. With relay bypassed, there should be continuity across the AC cord blades (Figure 6-11, Page 6-15). Figure 6-11 AC Cord Test 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-15...
  • Page 128 750V ç ç DIODE ( ) SETTING DIODE ( ) SETTING (AC) (AC) – – (AC) (AC) RECTIFIER RECTIFIER Figure 6-12 Rectifier Test Figure 6-13 Rectifier Test – Probes Reversed Page 6-16 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 129 POSITIVE PIN WAVETEK 1000 PULL HERE PULL HERE PULL HERE PULL HERE 2000 200k 200nA 1000 --- FUSED 750V ç NEGATIVE PIN DIODE ( ) SETTING Figure 6-14 DC Plug Test 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-17...
  • Page 130 4.1. To bypass the relay, remove the orange wire (3) from the AC circuit breaker and disconnect the brown wire (4) from the relay. Connect the brown wire (4) to the AC circuit breaker (Figure 6-16, Page 6-19). See following DANGER. Page 6-18 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 131 (AC) AC INPUT PLUG GREEN BLACK BLACK (DISCONNECTED FROM RELAY CASE – (AC) AND CONNECTED TO BREAKER) AC CORD GROUND RECTIFIER WHITE BROWN YELLOW Figure 6-16 Transformer Test Wiring Diagram 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-19...
  • Page 132 3. Disconnect the green wire (2) from charger case and position it so it does not touch any metal part of the charger (Figure 6-17, Page 6-20). WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 6-17 AC Cord and Plug Continuity Test Page 6-20 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 133 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-21...
  • Page 134 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. Page 6-22 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 135: Charger Repairs

    (Figure 6-6, Page 6-8). • Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle. 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-23...

  • Page 136: Dc Cord

    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-lb (1.2 N·m). Page 6-24 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 137: Rectifier

    • 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-25...

  • Page 138: Transformer

    • 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. Install the charger cover and check charger for proper operation. Page 6-26 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 139: Ammeter

    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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-27...

  • Page 140: Fuse

    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. Page 6-28 2005 Domestic Battery Charger Maintenance and Service Manual...

  • Page 141: Charger Relay

    5. Disconnect the AC cord green wire from the charger base. 6. Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger. 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-29...

  • Page 142: 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. Page 6-30 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 143 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. 2005 Domestic Battery Charger Maintenance and Service Manual Page 6-31...
  • Page 144 See Section 11 – Electrical System and Testing in the appropriate maintenance and service manual. Page 6-32 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 145 ..........5-20 removal ............6-24 battery charger testing ............ 6-17, 6-21 identification ............2-4 electrical system installation ............5-4 charge circuit ............6-3 repairs ..............5-23 fuse specifications .............2-1 installation ............6-28 removal ............6-28 testing ..............5-7 2005 Domestic Battery Charger Maintenance and Service Manual Page i-1...
  • Page 146 4 – rectifier ..........5-16, 6-16 see circuit breaker 5 – DC circuit continuity test ....5-17, 6-17 6 – transformer ........5-18, 6-18 CAUTION 7 – battery state of charge ......5-20, 6-20 definition of ............1-1 Page i-2 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 147 4 – diodes ............3-16 circuit breaker 5 – DC circuit continuity test ......3-18 installation ............4-27 6 – transformer ..........3-18 removal ............4-27 7 – battery state of charge .......3-20 testing ..............4-21 2005 Domestic Battery Charger Maintenance and Service Manual Page i-3...
  • Page 148 AC cord with retractable cord reel ....4-16 AC cord without retractable cord reel ..4-17 ammeter ............4-21 DC cord ............4-20 relay ............4-21 retractable cord reel ........4-19 transformer ..........4-20 Page i-4 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 149 2005 Domestic Battery Charger Maintenance and Service Manual...
  • Page 151 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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