Club Car 2008 Export Battery Charger Maintenance Service Manual
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Club Car 2008 Export Battery Charger Maintenance Service Manual

Club Car 2008 Export Battery Charger Maintenance Service Manual

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EXPO RT
®
&
BAT TE RY C H A R G E R S
2008 MAINTENANCE & SERVICE MANUAL
Manual No. 103373122
Edition Code 0408A00000

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Summary of Contents for Club Car 2008 Export Battery Charger

  • Page 1 EXPO RT ® & BAT TE RY C H A R G E R S 2008 MAINTENANCE & SERVICE MANUAL Manual No. 103373122 Edition Code 0408A00000...
  • Page 3 Car factory-trained technician. It is the policy of Club Car, Inc. 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    DC Cord and Plug Inspection ....................... 3-12 Checking Battery Condition After a Charge Cycle ................3-14 Start Charge Cycle ........................3-14 Troubleshooting ..........................3-14 Test Procedures ..........................3-18 Index of Test Procedures ......................3-18 2008 Export Battery Charger Maintenance and Service Manual Page iii...
  • Page 6 Charger AC Cord and Retractable Cord Reel ................4-32 Charging a Battery Pack that has Low Voltage ................4-33 Onboard Charger Removal and Installation ..................4-35 DS Villager 4 ..........................4-35 Precedent Vehicles ........................4-36 Page iv 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 7 Onboard Charger Operation ......................Onboard Charger AC Power Connection ..................Charging Batteries ........................Testing Charger Operation ......................Checking Battery Condition with an Onboard Charger ..............Start Charge Cycle ........................Troubleshooting ..........................2008 Export Battery Charger Maintenance and Service Manual Page v...
  • Page 8 Charger AC Cord and Retractable Cord Reel ................6-29 Charging a Battery Pack that has Low Voltage ................6-31 Onboard Charger Removal and Installation ..................6-34 SECTION i – INDEX Page vi 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 9: Section 1 - Safety

    - 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 Export Battery Charger Maintenance and Service Manual Page 1-1...
  • Page 10 • Do not use a battery charger if it has received a sharp blow, was dropped, or was otherwise damaged. Make sure it is operating properly before putting it back in use. WARNING CONTINUED ON NEXT PAGE... Page 1-2 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 11 ý CAUTION • Be sure to check the batteries and charger monthly to maintain correct battery water level and ensure the charger is operating correctly during storage. 2008 Export Battery Charger Maintenance and Service Manual Page 1-3...
  • Page 12 2. Remove negative battery cable. 2. Remove negative battery cable. 3. Remove positive battery cable. 3. Remove positive battery cable. Connect battery cables in reverse order. Connect battery cables in reverse order. Page 1-4 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 13 2. Remove negative battery cable. 2. Remove negative battery cable. 3. Remove positive battery cable. 3. Remove positive battery cable. Connect battery cables in reverse order. Connect battery cables in reverse order. 2008 Export Battery Charger Maintenance and Service Manual Page 1-5...
  • Page 14 2. Remove negative battery cable. 2. Remove negative battery cable. 3. Remove positive battery cable. 3. Remove positive battery cable. Connect battery cables in reverse order. Connect battery cables in reverse order. Page 1-6 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 15: Specifications

    DC current (amps) (end of charge cycle) DIMENSIONS/WEIGHT Case – overall length 10.25 in. (26 cm) 10.25 in. (26 cm) Case – overall width 8.687 in. (22.1 cm) 8.687 in. (22.1 cm) 2008 Export Battery Charger Maintenance and Service Manual Page 2-1...

  • Page 16: Section 2 - Charger Identification And Specifications

    (22.1 cm) (22.1 cm) (22.1 cm) 9.437 in. 9.437 in. 9.437 in. 9.437 in. Case – overall height (24 cm) (24 cm) (24 cm) (24 cm) Specifications continued on next page... Page 2-2 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 17 (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) • • • • 2008 Export Battery Charger Maintenance and Service Manual Page 2-3...
  • Page 18 (261.6 cm) (365.8 cm) 34.8 lb 35.3 lb Weight (15.8 kg) (16.0 kg) MOUNTING CONFIGURATION Mounting: Set on shelf, wall mount with keyhole, or hang securely from ceiling. • • Page 2-4 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 19 (24.1 cm) 17 ft. (5.2 m) AC cord length (retractable) 21.5 in. DC cord length (54.6 cm) 37.0 lb Weight (16.8 kg) MOUNTING CONFIGURATION Mounting: Onboard (secured to the vehicle) • 2008 Export Battery Charger Maintenance and Service Manual Page 2-5...

  • Page 20: Battery Charger Identification

    Do not attempt to service a battery charger that cannot be properly identified. If a charger cannot be identified, contact your local Club Car dealer or distributor. BATTERY CHARGER NAME...

  • Page 21: Section 3 - Export Powerdrive Battery Charger (External)

    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.

  • Page 22: Powerdrive Charger Features

    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.

  • Page 23: The Charge Circuit

    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 Export Battery Charger Maintenance and Service Manual Page 3-3...

  • Page 24: Turf 1 And Carryall 1

    #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 Export Battery Charger Maintenance and Service Manual...

  • Page 25: Precedent - 4 X 12-Volt

    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 Export Battery Charger Maintenance and Service Manual Page 3-5...

  • Page 26: Precedent - 6 X 8-Volt

    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 Export Battery Charger Maintenance and Service Manual...

  • Page 27: Limo - 6 X 8-Volt

    Check the connections between the 18-gauge gray wire from the charger recep- tacle, the sense lead fuse, and the 18-gauge gray wire from the onboard computer. In addition, check the charger receptacle fuse link and its connections. 2008 Export Battery Charger Maintenance and Service Manual Page 3-7...
  • Page 28 TERMINAL #6 BLACK CHARGER RECEPTACLE #10 BLACK #10 BLACK #18 GRAY #18 GRAY #10 RED SENSE LEAD FUSE – Figure 3-7 Charge Circuit and Battery Configuration – Limo Electric Vehicles Page 3-8 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 29: Charger Installation And Operation

    • 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. 2008 Export Battery Charger Maintenance and Service Manual Page 3-9...

  • Page 30: Ac Power Connection

    NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. 220 V...

  • Page 31: Charging Batteries

    2. Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel (Figure 3-8, Page 3-10). The charger will activate automatically within 2 to 15 seconds after the DC plug is connected. See following WARNING. 2008 Export Battery Charger Maintenance and Service Manual Page 3-11...

  • Page 32: Testing Charger Operation

    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.
  • Page 33 BLACK BLACK BLACK BLACK(1) BLACK(1) BLACK (1) AC CIRCUIT BLACK BREAKERS BLACK BLACK BLACK TAN (6) BLACK BLACK BLACK BLACK (6) BLACK (6) Figure 3-11 PowerDrive Export Charger Wiring Diagram 2008 Export Battery Charger Maintenance and Service Manual Page 3-13...

  • Page 34: Checking Battery Condition After A Charge Cycle

    Use the following Troubleshooting Guide for troubleshooting export PowerDrive external battery chargers (model numbers 18780-11 and 18780-18). The Troubleshooting Guide encompasses the entire battery charging circuit. Test procedures specified in the Troubleshooting Guide can be found on the following pages. Page 3-14 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 35 3-26 Single charger fuse link blows Test Procedure 4A – Single Diode Failure Diode failed on page 3-22 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page... 2008 Export Battery Charger Maintenance and Service Manual Page 3-15...
  • Page 36 (25 seconds, at 10 second intervals for Onboard computer malfunction page 3-21 Precedent vehicles) See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual Page 3-16 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 37 EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL) Troubleshooting DIODE AND HEATSINK PRIMARY COIL SECONDARY COIL TRANSFORMER AMMETER FUSE AND LENS ASSEMBLY RELAY DC CORD Figure 3-12 PowerDrive Battery Charger (Export) – Exploded View 2008 Export Battery Charger Maintenance and Service Manual Page 3-17...

  • Page 38: Test Procedures

    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 3-18 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 39 (Figure 3-15, Page 3-19 and Figure 3-16, Page 3-19). FRONT FRONT OF VEHICLE OF VEHICLE Figure 3-15 Turf 1 and Carryall 1 Battery Voltage Test Figure 3-16 Limo Battery Voltage Test 2008 Export Battery Charger Maintenance and Service Manual Page 3-19...
  • Page 40 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 3-37. Page 3-20 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 41 5.2.6. Use a jumper wire with alligator clips to connect the black wire from relay terminal 7 to the blue wire from relay terminal 4. 5.3. With relay bypassed, there should be continuity across the AC cord blades (Figure 3-20, Page 3-22). 2008 Export Battery Charger Maintenance and Service Manual Page 3-21...
  • Page 42 If a diode does not conduct current (does not show continuity) in either direction, the entire heatsink must be replaced. Page 3-22 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 43 5. Ensure that the charger and vehicle are wired properly and all connections are clean and tight. TEST PROCEDURE 5 – CHARGER DC CIRCUIT CONTINUITY TEST See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1. 2008 Export Battery Charger Maintenance and Service Manual Page 3-23...
  • Page 44 3. Disconnect transformer secondary coil wires from the heatsink (Figure 3-25, Page 3-25). 4. To apply AC power directly to the transformer primary coil, bypass the relay. See Charging a Battery Pack that has Low Voltage on page 3-37. See following DANGER. Page 3-24 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 45 TEST PROCEDURE 7 – BATTERY STATE OF CHARGE TEST See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1. 2008 Export Battery Charger Maintenance and Service Manual Page 3-25...
  • Page 46 AC cord and plug must be replaced. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING AC plug may have different appearance depending on geographic region. Figure 3-26 AC Plug Page 3-26 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 47 DC CORD BLUE WIRE TO BLUE WIRE OF VOLTAGE SUPPRESSOR ASSEMBLY CONNECTED TO RELAY DC CORD BLACK WIRE TO AMMETER DC CORD RED WIRE TO HEAT SINK Figure 3-27 DC Cord 2008 Export Battery Charger Maintenance and Service Manual Page 3-27...
  • Page 48 (tan). The tester should indicate continuity on both secondary coil wires. If tester does not indicate continuity on both secondary coil wires, replace transformer. Ensure that the fuse is intact and not blown. Page 3-28 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 49 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. 2008 Export Battery Charger Maintenance and Service Manual Page 3-29...

  • Page 50: Charger Repairs

    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 3-27, Page 3-27). Page 3-30 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 51: Heatsink

    4. Connect the other secondary coil transformer wire (tan) to the top terminal post of the heatsink. Tighten nut to 18 in-lb (2.0 N·m). 5. Install the charger cover and check charger for proper operation. 2008 Export Battery Charger Maintenance and Service Manual Page 3-31...

  • Page 52: Transformer

    • 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. 11. Install the charger cover and check charger for proper operation. Page 3-32 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 53: Ammeter

    • 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. 2008 Export Battery Charger Maintenance and Service Manual Page 3-33...

  • Page 54: Fuse Link

    5. Disconnect the voltage suppressor wire assembly from charger relay. Voltage Suppressor Installation Install in reverse order of removal. Tighten nut attaching voltage suppressor (18-gauge red wire) to heatsink to 18 in-lb (2.0 N·m). Page 3-34 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 55: Charger Relay

    6. Repeat step 5 for the removal of the bottom circuit breaker. AC Circuit Breaker Installation Install in reverse order of removal. 2008 Export Battery Charger Maintenance and Service Manual Page 3-35...

  • Page 56: Charger Ac Cord

    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. Page 3-36 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 57: Charging A Battery Pack That Has Low Voltage

    DC cord from the charger receptacle in the vehicle. 8. Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the relay (Figure 3-31, Page 3-38). See following WARNING. 2008 Export Battery Charger Maintenance and Service Manual Page 3-37...
  • Page 58 BLACK BLACK(1) BLACK(1) BLACK (1) AC CIRCUIT BLACK BREAKERS BLACK BLACK BLACK TAN (6) BLACK BLACK BLACK BLACK (6) BLACK (6) Figure 3-31 Export PowerDrive Charger Wiring Diagram (Relay Bypassed) Page 3-38 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 59: Section 4 - Export Powerdrive Charger (Onboard)

    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 DS and Prece- dent vehicles, contact your local Club Car dealer or distributor.

  • Page 60: Powerdrive Onboard Charger Features

    (+) 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 Export Battery Charger Maintenance and Service Manual...
  • Page 61 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 Export Battery Charger Maintenance and Service Manual Page 4-3...

  • Page 62: Charger Operation

    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- Page 4-4 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 63: Normal Charger Operation

    NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. 220 V...

  • Page 64: Testing Charger Operation

    (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;...
  • Page 65 TAN (1) BLACK BLACK BLACK BLACK(1) BLACK (1) AC CIRCUIT BLACK BREAKERS BLACK TAN (6) BLACK BLACK BLACK BLACK (6) BLACK (6) Figure 4-5 Export PowerDrive Onboard Battery Charger Wiring Diagram 2008 Export Battery Charger Maintenance and Service Manual Page 4-7...

  • Page 66: Checking Battery Condition

    Use the following Troubleshooting Guide for troubleshooting export PowerDrive onboard battery chargers (model numbers 17790-10 and 17790-40). The Troubleshooting Guide encompasses the entire battery charging circuit. Test procedures specified in the Troubleshooting Guide can be found on the following pages. Page 4-8 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 67 4-21 Single charger fuse link blows Test Procedure 4A – Single Diode Failure Diode failed on page 4-16 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page... 2008 Export Battery Charger Maintenance and Service Manual Page 4-9...
  • Page 68 See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual Batteries are getting close to full Recharge batteries as soon as possible discharge capacity Page 4-10 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 69: Test Procedures

    34 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 4-33. 2008 Export Battery Charger Maintenance and Service Manual Page 4-11...
  • Page 70 1. RED probe to battery no. 1 (+). 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 4 (-). 2. BLACK probe to battery no. 4 (-). Page 4-12 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 71 2. Place black (–) probe of multimeter on terminal with blue DC cord wire and red (+) probe to terminal with red relay wire (Figure 4-10, Page 4-14). 3. Multimeter should indicate full battery voltage (approximately 47-50 volts). If reading is incorrect, replace control board. 2008 Export Battery Charger Maintenance and Service Manual Page 4-13...
  • Page 72 BLUE WIRE TO RELAY BLACK WIRE TO RELAY RED WIRE TO RELAY WHITE OR BLUE WIRE OF AC CORD RED WIRE TO HEATSINK BLUE WIRE TO DC CORD Figure 4-12 Control Board Page 4-14 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 73 • The relay wiring must be properly connected prior to placing the charger back into normal service. Failure to remove the jumper wire and properly connect the relay wiring could result in property damage, severe personal injury, or death. 2008 Export Battery Charger Maintenance and Service Manual Page 4-15...
  • Page 74 8. Ensure the charger is wired properly and all connections are clean and tight. See following CAUTION. CAUT ION • If connections are not clean and tight, excessive heat will be created and the charger may become damaged. Page 4-16 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 75 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 Export Battery Charger Maintenance and Service Manual Page 4-17...
  • Page 76 CORD CORD RED WIRE RED WIRE BLACK WIRE BLACK WIRE Figure 4-16 DC Cord Test – DS Villager 4 Figure 4-17 DC Cord Test (Probes Reversed) – DS Villager 4 Page 4-18 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 77 7. If the AC line fuse does not blow or the AC circuit breaker does not trip, check the transformer secondary coil voltage. 2008 Export Battery Charger Maintenance and Service Manual Page 4-19...
  • Page 78 NOTE: Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps. See Batteries section in the appropriate maintenance and service manual. Page 4-20 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 79 Disconnect the green or green/yellow wire (2) from charger case and position it so it does not touch any metal part of the charger (Figure 4-21, Page 4-22). 2008 Export Battery Charger Maintenance and Service Manual Page 4-21...
  • Page 80 Figure 4-19 AC Cord and Retractable Cord Reel Continuity Test Figure 4-20 Heatshrink Removal WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 4-21 Short AC Cord Test Page 4-22 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 81 If any other reading is obtained, the cord reel must be replaced. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 OHM SETTING Figure 4-22 Retractable Cord Reel Test 2008 Export Battery Charger Maintenance and Service Manual Page 4-23...
  • Page 82 See Onboard Charger Removal on page 4-35. 2. Remove the charger cover. 3. Remove the transformer (tan) secondary coil wire from the upper terminal of the heatsink (Figure 4-5, Page 4-7). Page 4-24 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 83 4. Place the continuity tester clip on one of the ammeter posts. 5. Place the continuity test probe on the other ammeter post. The tester should indicate continuity. If the tester does not indicate continuity, replace the ammeter. 2008 Export Battery Charger Maintenance and Service Manual Page 4-25...

  • Page 84: Charger Repairs

    4. Attach black wire of the new DC cord to ammeter. Install nut (1) onto post of ammeter slightly more than finger tight. While holding the inside nut (2), tighten the outside nut (1) 1/4 turn (Figure 4-24, Page 4-27). See following CAUTION. Page 4-26 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 85: Heatsink

    2. Connect the red wire from the DC cord and the red wire from the control board to the center terminal post on the heatsink (Figure 4-5, Page 4-7). Tighten nut to 18 in-lb (2.0 N·m). 2008 Export Battery Charger Maintenance and Service Manual Page 4-27...

  • Page 86: Transformer

    9. Set the voltage selector switch to the appropriate voltage matching the incoming AC electrical service that will be used to power the charger. 10. Tie the wires together as they were before the wire tie was removed. See following WARNING. Page 4-28 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 87: Ammeter

    3. Connect the DC cord black wire (5) to the left (as viewed from inside the charger) post of the ammeter. 4. Connect the buss bar (3) from the fuse link to the right post of the ammeter. Place flat washers on both sides of the buss bar. 2008 Export Battery Charger Maintenance and Service Manual Page 4-29...

  • Page 88: Fuse Link

    2. Remove the charger cover. 3. Disconnect all wires from the relay (Figure 4-26, Page 4-31). 4. Remove the two screws and nuts attaching relay to mounting bracket. 5. Remove the relay. Page 4-30 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 89: Charger Ac Circuit Breaker

    6. Repeat step 5 for the removal of the bottom circuit breaker. AC Circuit Breaker Installation Install in reverse order of removal. 2008 Export Battery Charger Maintenance and Service Manual Page 4-31...

  • Page 90: Charger Ac Cord And Retractable Cord Reel

    (Figure 4-20, Page 4-22). 4. Disconnect the short AC cord from the retractable cord reel. Retractable AC Cord Reel Installation Install in reverse order of removal. Page 4-32 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 91: Charging A Battery Pack That Has Low Voltage

    Onboard Charger Removal on page 4-35. See WARNING on page 4-26. 9. Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the relay (Figure 4-27, Page 4-34). See following WARNING. 2008 Export Battery Charger Maintenance and Service Manual Page 4-33...
  • Page 92 TAN (1) BLACK BLACK BLACK BLACK(1) BLACK (1) AC CIRCUIT BLACK BREAKERS BLACK TAN (6) BLACK BLACK BLACK BLACK (6) BLACK (6) Figure 4-27 PowerDrive Onboard Charger Wiring Diagram (Relay Bypassed) Page 4-34 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 93: Onboard Charger Removal And Installation

    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 4-29, Page 4-36). 6. Cut any wire tie(s) that secures the DC cord to the vehicle. 7. Lift charger and reel assembly from vehicle. 2008 Export Battery Charger Maintenance and Service Manual Page 4-35...

  • Page 94: Precedent Vehicles

    2. Disconnect the charger DC cord at the three pin connector (1) (Figure 4-30, Page 4-37). 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 4-36 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 95 2. Install four bolts (2) and nuts (5) securing charger to chassis and tighten to 108 in-lb (12 N·m). 3. Connect battery cables, positive (+) cable first, and tighten to 110 in-lb (12.4 N·m). Figure 4-30 Onboard Charger Mounting – Precedent Vehicles 2008 Export Battery Charger Maintenance and Service Manual Page 4-37...

  • Page 97: Section 5 - Export Iq Plus Charger (External)

    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 IQ Plus 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.

  • Page 98: Iq Plus External Charger Features

    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.

  • Page 99: The Charge Circuit

    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 5-2 Charge Circuit 2008 Export Battery Charger Maintenance and Service Manual Page 5-3...

  • Page 100: External Charger Installation And Operation

    WARNING • Do not bypass the sense lead fuse. • 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.

  • Page 101: Ac Power Connection

    NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. With charger DC cord disconnected, connect the power supply cord to an AC supply within the acceptable voltage range.

  • Page 102: Charging Batteries

    2. Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel (Figure 5-4, Page 5-7). The charger will activate automatically within 2 to 15 seconds after the DC plug is connected. See following WARNING. Page 5-6 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 103 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;...

  • Page 104: External Charger Plug And Receptacle

    Normal battery voltage near the end of a charge cycle should be approximately 59 to 63 volts DC. START CHARGE CYCLE 1. Disconnect the DC plug from the vehicle charger receptacle. 2. Wait 20 seconds, then reconnect the DC cord to the vehicle receptacle. See following NOTE. Page 5-8 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 105: Testing Charger Operation

    (Figure 5-2, Page 5-3) and that the internal charger wiring is correct (Figure 5-6, Page 5-9). Figure 5-6 Export IQ Plus Battery Charger Wiring Diagram (External Charger) 2008 Export Battery Charger Maintenance and Service Manual Page 5-9...

  • Page 106: Troubleshooting

    Use the following Troubleshooting Guide for troubleshooting export IQ Plus external battery chargers (model numbers 25880-11 and 25880-18). The Troubleshooting Guide encompasses the entire battery charging cir- cuit. Test procedures specified in the Troubleshooting Guide can be found on the following pages. Page 5-10 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 107 5-22 Single charger fuse link blows Test Procedure 4A – Single Diode Failure Diode failed on page 5-18 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page... 2008 Export Battery Charger Maintenance and Service Manual Page 5-11...
  • Page 108 (25 seconds, at 10 second intervals for Onboard computer malfunction page 5-17 Precedent vehicles) See Batteries section in the appropriate Battery or batteries need to be replaced maintenance and service manual Page 5-12 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 109 EXPORT IQ PLUS CHARGER (EXTERNAL) Troubleshooting Figure 5-7 IQ Plus Battery Charger (Export) – Exploded View 2008 Export Battery Charger Maintenance and Service Manual Page 5-13...

  • Page 110: Test Procedures

    3.3. Verify the 10-gauge red wire of the charger receptacle is connected to the main harness red wire at three wire plug. 3.4. Make sure the two nuts that secure the two 10-gauge black wires to the receptacle fuse assembly are tight (Figure 5-8, Page 5-15). Page 5-14 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 111 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 5-34. 2008 Export Battery Charger Maintenance and Service Manual Page 5-15...
  • Page 112 OF VEHICLE Place multimeter red (+) probe here. Place multimeter black (–) probe here. FRONT OF VEHICLE TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES Figure 5-9 IQ Plus Battery Configuration Page 5-16 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 113 5.2. Bypass the relay. See step 4 of Charging a Battery Pack that has Low Voltage on page 5-34. 5.3. With relay bypassed, there should be continuity across the AC cord blades (Figure 5-10, Page 5-18). 2008 Export Battery Charger Maintenance and Service Manual Page 5-17...
  • Page 114 4. Using a low voltage continuity tester or multimeter set to the diode test function, connect the red (+) test probe to the diode mounting plate and the black (–) test probe to a diode terminal and note the reading (Figure 5-11, Page 5-19). Page 5-18 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 115 4. 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). 5. Ensure that the charger and vehicle are wired properly and all connections are clean and tight. 2008 Export Battery Charger Maintenance and Service Manual Page 5-19...
  • Page 116 4. To apply AC power directly to the transformer primary coil, bypass the relay. See step 4 of Charging a Battery Pack that has Low Voltage on page 5-34. See following DANGER. Page 5-20 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 117 • The relay wiring must be properly connected prior to placing the charger back into normal service. Failure to remove the jumper wire and properly connect the relay wiring could result in property damage, severe personal injury, or death. 2008 Export Battery Charger Maintenance and Service Manual Page 5-21...
  • Page 118 AC cord. Test for continuity on each of the flat blades and on the round pin of the AC plug. The tester should indicate continuity on only one flat blade. If any other reading is obtained, the AC cord has failed and must be replaced. Page 5-22 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 119 1. Disconnect the AC cord from the AC receptacle (on front of battery charger) and the incoming AC outlet. Disconnect the battery charger from the vehicle. 2. Disconnect black wire from charger relay terminal 4 (4) (Figure 5-18, Page 5-24 and Figure 5-6, Page 5-9). 2008 Export Battery Charger Maintenance and Service Manual Page 5-23...
  • Page 120 4. Disconnect the red wire (19) of the DC cord from the heatsink. 5. Disconnect the blue wire (18) from the limiter (15), which connects to the red wire assembly that connects to the charger relay. Page 5-24 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 121 6. If the continuity readings agree with the chart, replace the voltage selector switch. If the continuity read- ings differ from the chart, replace the transformer. 2008 Export Battery Charger Maintenance and Service Manual Page 5-25...
  • Page 122 (Figure 5-6, Page 5-9). Place continuity tester leads on terminals 6 and 8 of the relay. The tester should indicate no continuity. If tester indicates continuity, the relay contacts have failed closed and the relay must be replaced. Page 5-26 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 123: Charger Repairs

    3. Remove the DC cord black wire (17) from the ammeter by loosening the nut. Support the terminal as the nut is loosened to prevent rotation of the connection (Figure 5-19, Page 5-25). 4. Remove nut attaching the red wire (19) of DC cord onto the heatsink. 2008 Export Battery Charger Maintenance and Service Manual Page 5-27...

  • Page 124: Heatsink

    Install the nuts and bolts that secure the heatsink to the case. Tighten the bolts to 22 in-lb (2.5 N·m) (Figure 5-6, Page 5-9 and Figure 5-7, Page 5-13). Page 5-28 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 125: Transformer

    9. Set the voltage selector switch to the appropriate voltage matching the incoming AC electrical service that will be used to power the charger. 10. Tie the wires together as they were before the wire tie was removed. See following WARNING. 2008 Export Battery Charger Maintenance and Service Manual Page 5-29...

  • Page 126: Ammeter

    3. Connect the two black wires to the ammeter posts. 4. Thread nuts onto both posts of the ammeter until just past finger tight. While holding the inside nut, tighten the outside nut 1/4 turn. See following CAUTION. Page 5-30 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 127: Fuse Link

    5. Disconnect the voltage suppressor wire assembly from charger relay (3). 6. Remove the white fiberglass sleeve from the red heatsink wire. Retain the sleeve for use when installing the new voltage suppressor. 2008 Export Battery Charger Maintenance and Service Manual Page 5-31...

  • Page 128: Charger Relay

    See General Warning, Section 1, Page 1-1. See additional WARNING on page 5-1. AC Circuit Breaker Removal 1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. See WARNING on page 5-27. 2. Remove the charger cover. Page 5-32 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 129: Ac Charger Receptacle

    2. Connect the green/yellow (ground) wire to the center terminal of the AC charger receptacle. 3. Connect the two black wires to the bottom terminals of the AC charger receptacle. 4. Install the charger cover. 2008 Export Battery Charger Maintenance and Service Manual Page 5-33...

  • Page 130: Charging A Battery Pack That Has Low Voltage

    DC cord from the charger receptacle in the vehicle. 8. Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the relay (Figure 5-22, Page 5-35). See following WARNING. Page 5-34 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 131 See Section 11 – Electrical System and Testing in the appropriate maintenance and service manual. 2008 Export Battery Charger Maintenance and Service Manual Page 5-35...

  • Page 133: Section 6 - Export Iq Plus Charger (Onboard)

    Do not attempt to service a battery charger that has not been prop- erly identified. If a charger cannot be properly 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.

  • Page 134: Iq Plus Onboard Charger Features

    • 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. THE CHARGE CIRCUIT For vehicles with onboard chargers, the charge circuit consists of the following components: •...

  • Page 135: Onboard Charger Operation

    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.

  • Page 136: Onboard Charger Ac Power Connection

    NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. Connect the power supply cord to an AC supply within the acceptable voltage range. See Section 2 –...

  • Page 137: Charging Batteries

    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...

  • Page 138: Testing Charger Operation

    TAN (1) BLACK BLACK BLACK (1) BLACK(1) AC CIRCUIT BLACK BREAKERS BLACK TAN (6) BLACK BLACK BLACK BLACK (6) BLACK (6) Figure 6-4 Export IQ Plus Onboard Battery Charger Wiring Diagram Page 6-6 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 139: Checking Battery Condition With An Onboard Charger

    Use the following Troubleshooting Guide for troubleshooting the export IQ Plus onboard battery charger (model number 25660-40). The Troubleshooting Guide encompasses the entire battery charging circuit. Test procedures specified in the Troubleshooting Guide can be found on the following pages. 2008 Export Battery Charger Maintenance and Service Manual Page 6-7...
  • Page 140 DC cord is wired in reverse polarity Check battery charger wiring Test Procedure 4B – Both Diodes Failed Both diodes failed on page 6-15 Troubleshooting Guide continued on next page... Page 6-8 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 141 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 2008 Export Battery Charger Maintenance and Service Manual Page 6-9...

  • Page 142: Test Procedures

    34 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 6-31. Page 6-10 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 143 (–) probe here. OF VEHICLE Place multimeter red (+) probe here. Place multimeter black (–) probe here. FRONT OF VEHICLE TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES Figure 6-5 Battery Configurations 2008 Export Battery Charger Maintenance and Service Manual Page 6-11...
  • Page 144 (+) probe to terminal from which the white or blue AC cord wire was disconnected (Figure 6-7, Page 6-12). 4. Connect AC cord to outlet. Reading should be input voltage from outlet. 5. If reading is incorrect, replace control board. Page 6-12 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 145 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 6-18. 2008 Export Battery Charger Maintenance and Service Manual Page 6-13...
  • Page 146 If a diode does not conduct current (does not show continuity) in either direction, the entire heatsink must be replaced. Page 6-14 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 147 DC cord is connected to the vehicle, whether or not the AC cord is plugged into an outlet. 4. On rare occasions, both diodes may fail as a result of a lightning strike at the charging location. 2008 Export Battery Charger Maintenance and Service Manual Page 6-15...
  • Page 148 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 6-16 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 149 • The relay wiring must be properly connected prior to placing the charger back into normal service. Failure to remove the jumper wire and properly connect the relay wiring could result in property damage, severe personal injury, or death. 2008 Export Battery Charger Maintenance and Service Manual Page 6-17...
  • Page 150 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. Page 6-18 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 151 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 6-15, Page 6-20). 2008 Export Battery Charger Maintenance and Service Manual Page 6-19...
  • Page 152 AC plug. The tester should indicate continuity on one flat blade only. If any other reading is obtained, the cord reel must be replaced. Page 6-20 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 153 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. 2008 Export Battery Charger Maintenance and Service Manual Page 6-21...
  • Page 154 If tester does not indicate continuity on both secondary coil wires, replace transformer. Ensure that the fuse is intact and not blown. Page 6-22 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 155 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. 2008 Export Battery Charger Maintenance and Service Manual Page 6-23...

  • Page 156: Charger Repairs

    STRAIN RELIEF BUSHING Figure 6-17 DC Cord Figure 6-18 DC Cord Replacement DC Cord Installation 1. Insert the leads of the new DC cord through the hole in the charger base. Page 6-24 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 157: Heatsink

    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 6-34. 6. Check charger for proper operation. 2008 Export Battery Charger Maintenance and Service Manual Page 6-25...

  • Page 158: Transformer

    11. Install the charger cover and install the charger in the vehicle. See Onboard Charger Installation on page 6-34. 12. Check charger for proper operation. Page 6-26 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 159: Ammeter

    (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 Export Battery Charger Maintenance and Service Manual Page 6-27...

  • Page 160: Fuse Link

    5. Remove the relay. Charger Relay Installation Install in reverse order of removal. Connect wires as shown (Figure 6-20, Page 6-29). Tighten nuts securing relay to mounting bracket to 18 in-lb (2.0 N·m). Page 6-28 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 161: Charger Ac Circuit Breaker

    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 6-34. See WARNING on page 6-24. 2008 Export Battery Charger Maintenance and Service Manual Page 6-29...
  • Page 162 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 6-30 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 163: Charging A Battery Pack That Has Low Voltage

    4.6. Use a jumper wire with alligator clips to connect the black wire from relay terminal 7 to the black wire from relay terminal 4 (Figure 6-22, Page 6-33). See following DANGER. 2008 Export Battery Charger Maintenance and Service Manual Page 6-31...
  • Page 164 See Section 11 – Electrical System and Testing in the appropriate maintenance and service manual. Page 6-32 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 165 BLACK BLACK BLACK BLACK (1) BLACK(1) AC CIRCUIT BLACK BREAKERS BLACK BLACK TAN (6) BLACK BLACK BLACK (6) BLACK (6) Figure 6-22 IQ Plus Onboard Charger Wiring Diagram (Relay Bypassed) 2008 Export Battery Charger Maintenance and Service Manual Page 6-33...

  • Page 166: Onboard Charger Removal And Installation

    (Figure 6-23, Page 6-35). Slide the tubing over the connection and carefully apply heat to shrink it. 4. Connect battery cables, positive (+) cable first, and tighten to 110 in-lb (12.4 N·m). Page 6-34 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 167 Onboard Charger Removal and Installation VILLAGER 6 VILLAGER 8 AC Cord Reel TRANSPORTER 4 TRANSPORTER 6 CARRYALL 6 TURF 2/252 CARRYALL 2/252 XRT 900 Figure 6-23 Onboard Charger Mounting Details 2008 Export Battery Charger Maintenance and Service Manual Page 6-35...
  • Page 169 AC cord and plug .........5-22 state of charge test ..........5-22 ammeter ............5-27 battery charger DC cord ............5-24 operation ............5-6 relay .............5-26 repairs ..............5-27 transformer ..........5-25 testing ..............5-9 voltage suppressor ........5-26 2008 Export Battery Charger Maintenance and Service Manual Page i-1...
  • Page 170 ............6-28 heatsink battery condition after a charger cycle ..... 3-14 installation ............6-25 charging batteries that have low voltage ..3-37 removal ............6-25 state of charge test .......... 3-25 Page i-2 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 171 4 – diodes ............3-22 DC cord 5 – DC circuit continuity test ......3-23 installation ............4-26 6 – transformer ..........3-24 removal ............4-26 7 – battery state of charge .......3-25 testing ............ 4-18, 4-24 2008 Export Battery Charger Maintenance and Service Manual Page i-3...
  • Page 172 ........4-23 transformer ..........4-24 transformer installation ............4-28 removal ............4-28 testing .............. 4-19 troubleshooting ............ 4-8 specifications, battery charger ......2-1 suppressor, voltage see voltage suppressor Page i-4 2008 Export Battery Charger Maintenance and Service Manual...

  • Page 173: Section I - Index

    2. Ease of Finding Information 3. Clarity of Illustrations 4. Index Usability 5. Troubleshooting Chart Usability Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2008 Export Battery Charger Maintenance and Service Manual...
  • Page 176 Club Car, Inc. 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...

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