Charging A Battery Pack That Has Low Voltage - Club Car 2008-2011 Maintenance And Service Manual

POWERDRIVE CHARGER (ONBOARD)

CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE

See General Warning, Section 1, Page 1-1.
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WARNING
• Knowledge of battery charger wiring and component terminology is required before
attempting any repair (Figure 4-4, Page 4-6).
• Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet,
disconnect the DC cord from the vehicle, and remove the battery charger from the vehicle.
See Onboard Charger Removal on page 4-33.
If battery pack voltage is below 32 volts, the charger will not activate. The charger relay will have to be
bypassed to activate the charger.
1. Turn key switch OFF and place the Forward/Reverse handle in the NEUTRAL position.
2. Disconnect the AC and DC cords and remove the battery charger from the vehicle. See Onboard
Charger Removal on page 4-33. See WARNING on page 4-24.
3. Remove the charger cover.
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 4-26,
Page 4-32). 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. Install the charger cover and install the charger in the vehicle. See Onboard Charger Installation on
page 4-34.
6. Plug the AC cord into an electrical outlet. The charger should activate and begin charging.
7. Allow to charge 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.
8. After one or two hours, disconnect the AC cord and remove the battery charger from the vehicle. See
Onboard Charger Removal on page 4-33. See WARNING on page 4-24.
9. Disconnect the transformer wire (4) from AC circuit breaker and connect it to the relay. Connect the short
black wire (3) from the control board to the AC circuit breaker (Figure 4-4, Page 4-6). See following
WARNING.
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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.
2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charging a Battery Pack that has Low Voltage
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