Testing Charger Operation; Dc Cord And Plug Inspection - Club Car 2008-2011 Maintenance And Service Manual

POWERDRIVE CHARGER (EXTERNAL)

TESTING CHARGER OPERATION

1. With the DC plug disconnected from the vehicle charger receptacle, insert the AC cord into an outlet. The
charger relay should NOT close. A multimeter set to volts DC and connected across the DC plug positive
(+) and negative (–) pins should indicate zero volts. No transformer hum should be heard.
2. Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle. The charger relay
should close with an audible click after a 2 to 15 second delay. See following NOTE.
NOTE: Monitor the charge cycle to make sure the charger turns off properly. If the charge cycle is inter-
rupted, and the batteries are less than 90% charged, the battery warning light will illuminate inter-
mittently. See Battery Warning Light on page 3-2.
3. If the charger does not operate exactly as described above, refer to the wiring diagram and make sure
that the vehicle is wired correctly (Figure 3-2, Page 3-3 through Figure 3-6, Page 3-7) and that the
internal charger wiring is correct (Figure 3-9, Page 3-11).
DC CORD
AC CIRCUIT
BREAKER
AC INPUT PLUG
AC CORD
Figure 3-9 PowerDrive Battery Charger Wiring Diagram (External Charger)

DC CORD AND PLUG INSPECTION

The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them
for cracks, loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger
plug or receptacle show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts
and plug terminals should be cleaned with a good electrical contact cleaner. The plug should then be inserted
and removed several times to ensure ease of insertion, ease of removal, and good electrical contact. See
Charger Receptacle in Section 12 of the appropriate maintenance and service manual for receptacle
removal and installation. 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.
RED
RED
BLUE
BLACK
SECONDARY
RELAY
COIL
BLACK
PRIMARY
COIL
GREEN
CASE
GROUND
WHITE
2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charger Installation and Operation
DIODES WITH
HEATSINK
BLACK
BLACK
FUSE
TAN
TAN
3
AMMETER
Page 3-11