2008-2011 Domestic Battery Charger Maintenance and Service Manual L IS L IS R IA R IA 6 ,0 6 ,0 0 5& & 6, 1 6 ,1 R IT D IS . IN F IN “+ ”, T IV “- ”,...
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Car factory-trained technician. It is 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- 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.
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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.
DC Cord and Plug Inspection ....................... 3-11 Checking Battery Condition After a Charge Cycle ................3-12 Start Charge Cycle ........................3-12 Troubleshooting ..........................3-12 Test Procedures ..........................3-16 Index of Test Procedures ......................3-16 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page iii...
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Retractable AC Cord Reel ......................4-30 Charging a Battery Pack that has Low Voltage ................4-31 Onboard Charger Removal and Installation ..................4-33 DS Villager 4 ..........................4-33 Precedent Vehicles ........................4-34 Page iv 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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DS, 800, 810 and 850 Vehicles – 4 x 12-Volt ................Turf 1 and Carryall 1 Vehicles – 6 x 8-Volt ................... Precedent Vehicles – 4 x 12-Volt ....................Precedent Vehicles – 6 x 8-Volt ....................2008-2011 Domestic Battery Charger Maintenance and Service Manual Page v...
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Charger Installation and Operation ....................AC Power Connection ........................Charging Batteries ........................Testing Charger Operation ......................6-11 DC Cord and Plug Inspection ....................... 6-11 Checking Battery Condition After a charge Cycle ................6-12 Start Charge Cycle ........................6-12 Troubleshooting ..........................6-12 Test Procedures ..........................
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8-27 Voltage Suppressor ........................8-27 Charger Relay ..........................8-28 Charger AC Circuit Breaker ......................8-28 Charger AC Cord .......................... 8-28 Charging a Battery Pack that has Low Voltage ................8-29 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page vii...
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How To Identify Charge Algorithm Number .................. 10-3 The Charge Circuit ........................... 10-4 Onboard Charger Operation ......................10-4 Charger Displays .......................... 10-6 AC Power Connection ........................10-7 Charging Batteries ........................10-7 Page viii 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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Battery Troubleshooting Examples: 12-Volt Batteries ..............10-19 Battery Troubleshooting Examples: 8-Volt Batteries ..............10-20 Battery Troubleshooting Examples: 6-Volt Batteries ..............10-21 Charger Repairs ..........................10-22 Onboard Charger Removal and Installation ..................10-22 SECTION i – INDEX 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page ix...
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Page x 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
- 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...
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• 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...
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...
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.
31 lb 31.6 lb 33 lb Weight (14.1 kg) (14.3 kg) (15.0 kg) Mounting configuration Mounting: Set on shelf, wall mount with keyhole, or hang securely • • • from ceiling. Page 2-2 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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24 lb 24.6 lb 26 lb Weight (10.9 kg) (11.2 kg) (11.8 kg) Mounting configuration Mounting: Set on shelf, wall mount with keyhole, or hang securely • • • from ceiling. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 2-3...
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(264 cm) 104 in. 144 in. 240 in. DC cord length (264 cm) (365.8 cm) (609.6 cm) 24.25 lb. 24.7 lb. 25.35 lb. Weight (11 kg) (11.2 kg) (11.5 kg) Page 2-4 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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(264 cm) 104 in. 144 in. 240 in. DC cord length (264 cm) (365.8 cm) (609.6 cm) 24.0 lb. 24.5 lb. 26.0 lb. Weight (10.89 kg) (11.11 kg) (11.8 kg) 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 2-5...
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(24 cm) Weight 37 lb (16.8 kg) 37.7 lb (17.1 kg) 38.2 lb (17.3 kg) 37 lb (16.8 kg) Mounting Configuration Mounting: Onboard (secured to the vehicle) • • • • Page 2-6 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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(14.1 kg) (14.1 kg) (14.1 kg) Mounting configuration Mounting: 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...
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22.0 in. 22.0 in. DC cord length (55.8 cm) (55.8 cm) 37.0 lb 37.0 lb 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...
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Case – overall width 9.7 in. (24.6 cm) Case – overall height 4.3 in. (11 cm) Weight < 11 lbs (< 5 kg) Mounting configuration Mounting: Onboard Secured to the vehicle 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 2-9...
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.
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...
RECEPTACLE #10 BLACK #10 BLACK #18 GRAY #18 GRAY #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...
#10 BLACK #18 GRAY #18 GRAY #10 RED To Solenoid SENSE LEAD FUSE 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...
TO SOLENOID FRONT OF VEHICLE CHARGER RECEPTACLE BATTERY BANK SINGLE POSITION CONNECTOR ONBOARD COMPUTER SPEED 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...
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...
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OF VEHICLE RECEPTACLE BATTERY BANK TO SOLENOID 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...
• 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...
• 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...
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(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;...
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...
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.
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DC cord is wired in reverse polarity Check battery charger wiring Test Procedure 4B – Both Diodes Failed 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...
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10 second intervals for Onboard computer malfunction page 3-19 Precedent vehicles) See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual Page 3-14 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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TO RELAY TAN WIRE TO SECONDARY COIL PRIMARY COIL WIRES (TAN) 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...
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...
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(+) post of battery no. 1 and the negative (–) post of battery no. 6 (Figure 3-13, Page 3-17). Place multimeter red (+) 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...
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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...
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(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...
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7. Ensure that the charger is wired properly and all connections are clean and tight. See following CAU- TION. CAUT ION • 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...
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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...
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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. Page 3-22 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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3. 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). 4. Disconnect the red wire of the DC cord from the heatsink. Page 3-24 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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(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...
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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 3-26 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
DC CORD TO RED WIRE ASSEMBLY BLACK WIRE AT RELAY TO AMMETER DC CORD RED WIRE TO HEATSINK 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...
2. 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-lb (2.0 N·m). Page 3-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
• 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. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 3-29...
• 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 3-26 Ammeter Page 3-30 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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...
5. Disconnect the AC cord green wire from the charger base (Figure 3-27, Page 3-33). 6. 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...
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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...
BLACK AC CIRCUIT BREAKER SECONDARY RELAY COIL BLACK BLACK FUSE AMMETER PRIMARY COIL AC INPUT PLUG GREEN CASE AC CORD GROUND WHITE Figure 3-28 PowerDrive Charger Wiring Diagram (Relay Bypassed) Page 3-34 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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.
(+) post of battery no. 1. The blue 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...
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BLACK No. 10 RED GRAY RED TO No. 10 RED POSITIVE Three Pin TERMINAL Connector BLACK TO BATTERIES NEGATIVE ONBOARD TERMINAL – CHARGER Figure 4-3 Charge Circuit – Precedent Vehicles 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 4-3...
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...
(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;...
2. Wait 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...
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...
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Test Procedure 2 – Control Board on Onboard computer malfunction page 4-12 Test Procedure 7 – Battery State of Batteries may be fully charged Charge Test on page 4-18 Troubleshooting Guide continued on next page... Page 4-8 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
2. Control Board 3. AC Power and Continuity Check of AC Circuit 4. Diodes 5. Charger DC Circuit Continuity Test 6. Transformer 7. Battery State of Charge Test 8. Continuity 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 4-9...
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1.2. Verify the connection of the 10-gauge black wires 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...
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Figure 4-8 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 (-). 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 4-11...
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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 4-12 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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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 4-14 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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-lb (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...
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RED WIRE RED WIRE 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...
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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. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 4-17...
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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...
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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...
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POWERDRIVE CHARGER (ONBOARD) Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 4-18 AC Cord and Retractable Cord Reel Continuity Test Figure 4-19 Heatshrink Removal Page 4-20 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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 4-21...
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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...
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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...
DC CORD BLUE WIRE TO CONTROL BOARD DC CORD BLACK WIRE TO AMMETER DC CORD RED WIRE 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...
18 in-lb (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...
9. Install the charger cover and install the charger in the vehicle. See Onboard Charger Installation on page 4-34. 10. Check charger for proper operation. Page 4-26 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
(4) 1/4 turn. See following CAUTION. CAUT ION • Do not allow ammeter post to rotate as the nut is tightened. Rotation of the post could result in a damaged ammeter. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 4-27...
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-lb (2.0 N·m). Page 4-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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...
(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...
• 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...
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BLACK HEATSINK BLACK BLACK BLUE FUSE AMMETER CONTROL BOARD RELAY AC CIRCUIT BREAKER BLACK BLACK GREEN CASE WHITE GROUND AC CORD Figure 4-26 PowerDrive Onboard Charger Wiring Diagram (Relay Bypassed) Page 4-32 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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 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...
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...
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2. Install four bolts (2) and nuts (5) securing charger to chassis and tighten to 108 in-lb (12 N·m). 3. Connect the batteries. See Connecting The Batteries on page 1-4. Figure 4-29 Onboard Charger Mounting – Precedent Vehicles 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 4-35...
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.
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...
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 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 5-3...
• 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...
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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...
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...
(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;...
See also DC Cord Removal on page 5-23. See following NOTE. NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately. Page 5-8 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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.
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Test Procedure 4 – Rectifier on page 5-16 fuse link blows 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 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 5-11...
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 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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See Charging a Battery Pack that has Low Voltage on page 5-29. Place multimeter black (–) probe here. FRONT OF VEHICLE Place multimeter red (+) probe here. Figure 5-10 Precedent Battery Configuration Page 5-14 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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(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...
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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 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 5-17...
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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...
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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 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 5-19...
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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 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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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. Page 5-22 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
4. Remove the DC cord red wire from the ammeter. 5. Remove the DC cord blue wire from the blue wire located in the fiberglass sheathing. 6. Using pliers, squeeze the strain relief bushing and remove the DC cord. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 5-23...
3. Remove all four wires from the rectifier (Figure 5-6, Page 5-8). 4. Remove the nut (1), lock washer (2), and screw (3) from the rectifier and remove the rectifier from the heatsink (Figure 5-19, Page 5-25). Page 5-24 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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...
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...
(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...
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...
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...
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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...
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AC INPUT PLUG GREEN BLACK BLACK (DISCONNECTED FROM RELAY CASE – (AC) AND CONNECTED TO BREAKER) AC CORD GROUND RECTIFIER WHITE BLACK Figure 5-21 PowerDrive 2 Charger Wiring Diagram (Relay Bypassed) 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 5-31...
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.
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.
#10 BLACK #10 BLACK #18 GRAY #18 GRAY #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...
#18 GRAY #10 RED To Solenoid SENSE LEAD FUSE 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...
TO SOLENOID FRONT OF VEHICLE CHARGER RECEPTACLE BATTERY BANK SINGLE POSITION CONNECTOR ONBOARD COMPUTER SPEED CONTROLLER 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...
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...
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OF VEHICLE RECEPTACLE BATTERY BANK TO SOLENOID 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...
• 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...
• 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...
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(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;...
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...
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.
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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...
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10 second intervals for Onboard computer malfunction page 6-19 Precedent vehicles) See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual Page 6-14 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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RED WIRE TO AMMETER DC CORD SECONDARY GREEN WHITE WIRE TO BLUE WIRE COIL GROUND WIRE PRIMARY COIL TO RELAY Figure 6-10 PowerDrive 3 Battery Charger Components – Model 26560 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 6-15...
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...
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(+) 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...
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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...
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5.3. With relay bypassed, there should be continuity 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...
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POSITIVE PIN WAVETEK 1000 PULL HERE PULL HERE PULL HERE PULL HERE 2000 200k 200nA 1000 --- FUSED 750V ç NEGATIVE PIN DIODE ( ) SETTING Figure 6-20 DC Plug Test 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 6-21...
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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 6-22 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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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...
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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...
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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. Page 6-26 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
6. Using pliers, squeeze the strain relief bushing and remove the DC cord. DC CORD BLUE WIRE TO RELAY DC CORD BLACK DC CORD WIRE TO FUSE RED WIRE TO AMMETER STRAIN RELIEF BUSHING Figure 6-23 DC Cord 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 6-27...
4. Gently press the fuse link (2) toward the transformer to remove it from its mounting tab. 5. 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...
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...
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...
(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. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 6-31...
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...
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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...
• 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...
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AC CORD BREAKER RECTIFIER BLACK BLACK BLACK BLACK FUSE BROWN WHITE CASE GROUND 100 Ohm BLUE 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...
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.
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.
#10 BLACK #10 BLACK #18 GRAY #18 GRAY #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 Domestic Battery Charger Maintenance and Service Manual Page 7-3...
#18 GRAY #10 RED To Solenoid SENSE LEAD FUSE 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...
TO SOLENOID FRONT OF VEHICLE CHARGER RECEPTACLE BATTERY BANK SINGLE POSITION CONNECTOR ONBOARD COMPUTER SPEED CONTROLLER Figure 7-4 Charge Circuit and Style A Battery Configuration – 4 x 12-Volt Precedent Vehicles 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 7-5...
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...
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OF VEHICLE RECEPTACLE BATTERY BANK TO SOLENOID 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...
• 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...
• 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 Battery Charger Maintenance and Service Manual Page 7-9...
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(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;...
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...
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.
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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...
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10 second intervals for Onboard computer malfunction page 7-19 Precedent vehicles) See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual Page 7-14 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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CIRCUIT BREAKER COIL TO AMMETER DC CORD SECONDARY GREEN WHITE WIRE TO BLUE WIRE GROUND WIRE PRIMARY COIL COIL TO RELAY Figure 7-10 PowerDrive 3 Battery Charger Components – Model 26580 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 7-15...
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 7-16 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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(+) 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...
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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 Manual...
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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...
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7. Ensure that the charger is wired properly and all connections are clean and tight. See following CAU- TION. CAUT ION • 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...
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(+) 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...
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PULL HERE PULL HERE PULL HERE PULL HERE 2000 200k 200nA 1000 --- FUSED 750V ç NEGATIVE PIN DIODE ( ) SETTING Figure 7-21 DC Plug Test – Probes Reversed Page 7-22 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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• 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 7-23...
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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 7-33. Page 7-24 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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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...
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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 7-27...
6. Using pliers, squeeze the strain relief bushing and remove the DC cord. DC CORD BLUE WIRE TO RELAY DC CORD BLACK DC CORD WIRE TO FUSE RED WIRE TO AMMETER STRAIN RELIEF BUSHING Figure 7-23 DC Cord Page 7-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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-lb (2.0 N·m). 4. Install the charger cover and check charger for proper operation. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 7-29...
• 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 7-30 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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...
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...
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 7-33...
• 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...
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AC CORD BREAKER BLACK BLACK ORANGE ORANGE BLACK FUSE BROWN WHITE CASE GROUND 100 Ohm BLUE 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...
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.
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.
Villager 6 and 8 #18 GRAY #18 GRAY #6 RED #10 RED Turf 2 and 252 SENSE LEAD FUSE Carryall 2 and 252 XRT 900 BATTERIES – Figure 8-2 Charge Circuit 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 8-3...
ý 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.
• 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...
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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;...
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...
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.
Use the following Troubleshooting Guide for troubleshooting IQ Plus external battery chargers (model num- bers 25730-11, 25730-18, 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...
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DC cord is wired in reverse polarity Check battery charger wiring Test Procedure 4B – Both Diodes Failed 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...
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(with DC charger cord unplugged) Test Procedure 2 – Onboard Computer on Onboard computer malfunction page 8-15 See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 8-11...
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 8-12 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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Place multimeter red (+) probe here. Place multimeter black (–) probe here. FRONT OF VEHICLE TRANSPORTER 4 AND 6 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...
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(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...
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7. Ensure that the charger is wired properly and all connections are clean and tight. See following CAU- TION. CAUT ION • 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...
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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...
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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. Page 8-18 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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AC cord and plug must be replaced. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V (OHM) SETTING Figure 8-15 AC Cord and Plug Continuity Test Page 8-20 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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...
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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 8-22 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
DC CORD TO RED WIRE ASSEMBLY BLACK WIRE AT RELAY TO AMMETER DC CORD RED WIRE TO HEATSINK 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...
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 8-24 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
• 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. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 8-25...
• 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 8-18 Ammeter Page 8-26 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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...
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 8-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 8-29...
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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...
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 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...
ý 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.
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 15 seconds. Page 9-4 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
If you do not have this publication, contact your 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.
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 9-6 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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Test Procedure 2 – Control Board on Onboard computer malfunction page 9-11 Test Procedure 6 – Transformer on Failed transformer 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...
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See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual Batteries are getting close to full discharge Recharge batteries as soon as possible capacity Page 9-8 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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...
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OF VEHICLE Place multimeter red (+) probe here. Place multimeter black (–) probe here. FRONT OF VEHICLE TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES (STYLE A) Figure 9-4 Battery Configurations Page 9-10 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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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 approximately 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...
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• 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...
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8. Ensure that the charger is wired properly and all connections are clean and tight. See following CAU- TION. CAUT ION • If connections are not clean and tight, excessive heat will be created and the charger may become damaged. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 9-13...
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See General Warning, Section 1, Page 1-1. 1. Disconnect the AC cord from the wall outlet. 2. 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...
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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. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 9-15...
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• 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...
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10. If the 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...
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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...
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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...
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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...
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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...
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 9-16, Page 9-22). Page 9-22 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
18 in-lb (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...
See General Warning, 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...
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• 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 proper operation. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 9-25...
2. Remove the charger cover. 3. Disconnect all wires from the relay (Figure 9-19, Page 9-27). 4. Remove two nuts and lock washers securing relay to the charger base. 5. Remove the relay. Page 9-26 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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...
4. 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...
• 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...
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HEATSINK BLACK BLACK BLUE FUSE AMMETER CONTROL BOARD RELAY AC CIRCUIT BREAKER BLACK BLACK GREEN CASE WHITE GROUND AC CORD Figure 9-21 IQ Plus Onboard Charger Wiring Diagram (Relay Bypassed) Page 9-30 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
(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...
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VILLAGER 8 To AC Cord Reel Route behind batteries TRANSPORTER 4 TRANSPORTER 6 CARRYALL 6 TURF 2 AND 252 CARRYALL 2 AND 252 XRT 900 Figure 9-22 Onboard Charger Mounting Details Page 9-32 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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 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...
“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. Figure 10-2 80% LED Flashes in Algorithm Display Mode 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 10-3...
• Do not operate this charger if the AC supply cord is damaged or 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...
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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.
Short: <80% Charge. Flashing: Long: >80% Charge. Reduced Power Mode: Low AC Voltage or High internal Amber Flashing: charger temperature. Charger error. Reset charger power and refer to Flashing: Troubleshooting Instructions below. Page 10-6 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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.
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.
Reset charger (interrupt AC power for 15 seconds). Reset charger (interrupt AC power for 15 Charger Internal Fault seconds). Return to qualified service depot if fault persists. 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 10-9...
(–) 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...
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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...
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1.240 – 1.245 – 1.240 – 80 °F no.3 Cell Dead .000 does (26.7 °C) – Replace Battery = 1.240 = 1.245 not rise = 1.235 = 1.250 = 1.240 Page 10-12 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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Cell Dead 1.240 – 0 1.245 – 0 Float does 1.250 – 0 80 °F (26.7 °C) 0.000 – Replace Bat- = 1.240 = 1.245 not rise = 1.250 tery 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 10-13...
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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...
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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...
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...
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...
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 10-21...
Onboard Charger Installation – Precedent Vehicles 1. Installation is reverse of removal. 2. Tighten four lock nuts to 40 in-lb (5.4 N·m). 3. Connect the batteries. See Connecting The Batteries on page 1-4. Page 10-22 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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3 – on-charge battery voltage ......10-10 onboard computer 4 – hydrometer test ........10-11 testing ..............8-15 5 – discharge test ...........10-14 relay installation ............8-28 troubleshooting ..........10-9 12 volt battery troubleshooting examples ..10-19 removal ............8-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual Page i-1...
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5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No 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 Car’s Technical Publications Department 2008-2011 Domestic Battery Charger Maintenance and Service Manual...
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Club Car, LLC www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...