Battery Warning Light; The Charge Circuit; Charger Installation And Use - Club Car 1998 Maintenance And Service Manual Supplement

POWERDRIVE BATTERY CHARGER

BATTERY WARNING LIGHT

The PowerDrive vehicle features a dash mounted warning light (above steering column) which, when the vehicle is
in operation, indicates low battery voltage, or, when the vehicle is being charged, indicates a charging problem. The
battery warning light is controlled by the PowerDrive Plus onboard computer.
When the batteries receive an incomplete charge because 1) the DC power cord is disconnected, 2) AC power to the
charger is interrupted, 3) automatic charger shut-off occurs after 16 hours of operation, or 4) the charger malfunc-
tions, the warning light will indicate as follows:
• The warning light will not illuminate if the charge is 90% or more complete. The onboard computer will retain
in memory the amount of charge needed to fully replenish the batteries and will complete the charge during
the next charge cycle.
• When the charger DC cord is unplugged, the warning light will illuminate and remain illuminated for 10 sec-
onds if the charge is less than 90% complete but the vehicle has enough power for 60 minutes of operation.
This will alert the fleet operator that the vehicle may be used, but that it must be charged to completion as
soon as possible.
• The warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, if the charger times out at 16
hours and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and
batteries should be checked by your Club Car distributor/dealer.
• The warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (DC
plug is still connected) if AC power to the charger is interrupted. The warning light will go out when AC power
is restored.

THE CHARGE CIRCUIT

The vehicle charge circuit consists of the charger receptacle, fuse link, onboard computer and the batteries. The
negative terminal of the receptacle is connected to the onboard computer. The 10 gauge black wire from the
onboard computer connects to the B- terminal on the speed controller, and the 6 gauge black wire (also on the con-
troller B- terminal) goes through the onboard computer and connects to the negative (-) post of battery No. 6. The
positive terminal of the charger receptacle is connected to the positive post of battery No. 1. The gray wire (sense
lead) from the charger receptacle is connected to the sense lead fuse, which is connected to the gray wire from the
onboard computer. If the charger works with one vehicle, but does not work with another, then most likely the
problem is in the vehicle charge circuit. Check the connections between the 18 gauge gray wire from the charger
receptacle, the sense lead fuse and the 18 gauge gray wire from the onboard computer. Also check connections of
the fuse link assembly located on the charger receptacle (Figure 14-2, Page 14-5).

CHARGER INSTALLATION AND USE

Read DANGER and WARNING on page14-1.
WARNING
• DO NOT BYPASS THE SENSE LEAD FUSE!
• DISCONNECT BOTH THE AC AND DC PLUGS BEFORE WORKING ON THE CHARGER OR CHANGING THE CHARGER
CORD.
• TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE, GRASP THE PLUG AND PUSH IT STRAIGHT INTO
THE RECEPTACLE. DO NOT ROCK OR BEND THE PLUG.
WARNING CONTINUED ON FOLLOWING PAGE...
1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-3
14
The Charge Circuit