Club Car 2008-2011 Maintenance And Service Manual page 130

5
POWERDRIVE 2 CHARGER (EXTERNAL)
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WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 5-6, Page 5-8).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and
the DC plug from the vehicle charger receptacle.
1. Turn key switch OFF and place the Forward/Reverse handle in the NEUTRAL position. Leave the bat-
teries connected.
2. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
3. Remove the screws securing the charger cover and remove the cover from the charger.
4. To apply AC power directly to the transformer primary coil, the relay must be bypassed.
4.1. To bypass the relay, remove the black wire (3) from the AC circuit breaker and disconnect the black
wire (4) from the relay. Connect the black wire (4) to the AC circuit breaker (Figure 5-21,
Page 5-31). See following DANGER.
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DANGER
• Do not touch any wire or component in the battery charger while AC power is present. Failure
to heed this warning will result in an electric shock.
5. Plug the DC cord into the charger receptacle first, and then plug the AC cord into an electrical outlet.
6. The charger should activate and begin to charge the batteries. Allow the charger to operate for one or
two hours. See following WARNING.
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WARNING
• Do not leave the vehicle unattended while it is charging. A charger operating with a bypassed
relay could short circuit and possibly cause a fire.
7. After one or two hours, disconnect the charger AC cord from the electrical outlet first. Then disconnect
the DC cord from the charger receptacle in the vehicle.
8. Disconnect the transformer wire (4) from AC circuit breaker and connect it to the relay. Connect the short
black wire (3) from the relay to the AC circuit breaker (Figure 5-21, Page 5-31). See following WARN-
ING.
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WARNING
• The relay wiring must be properly connected prior to placing the charger back into normal
service. Failure to properly connect the relay wiring could result in property damage, severe
personal injury, or death.
9. Install the charger cover and the retaining screws.
10. Plug the DC cord into the charger receptacle and plug the AC cord into an electrical outlet.
11. Allow the charger to continue charging the batteries until the charger shuts off automatically.
12. When the charge cycle is complete, test the batteries again. If the battery pack voltage is above 34 volts
and the vehicle will not operate, it will be necessary to troubleshoot the vehicle's electrical system to
determine which electrical component has failed. See Section 11 – Electrical System and Testing in
the appropriate maintenance and service manual.
Page 5-30 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charging a Battery Pack that has Low Voltage