Club Car 1995 Golf Car, Maintenance Service Supplement

Page: 64 / 100

Battery/Charging Trouble Light
The PowerDrive System 48 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 Trouble Light is controlled by the PowerDrive System
48 on-board 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 opera-
tion, or 4) the charger malfunctions, the trouble light will indicate as follows:
• The trouble light will not come on if the charge is 90% or more complete. The on-board 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 is unplugged, the trouble light will come on and remain illuminated for 10 seconds if
the charge is less than 90% complete but the car has enough power to complete 36 holes of golf. This
will alert the fleet operator that the car may be used, but that it must be charged to completion as soon
as possible.
• The trouble light will come on and remain illuminated if the charger times out at 16 hours and the bat-
teries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries
should be checked by your Club Car distributor/dealer.
• The trouble light will come on during a charge cycle (DC plug is still connected) if AC power to the charg-
er is interrupted. The light will go out when AC power is restored.
THE CHARGE CIRCUIT
The vehicle charge circuit consists of the charger receptacle, fuse link, on-board computer, and the batter-
ies. The negative terminal of the receptacle is connected to the on-board computer. The No. 10 AWG black
wire from the on-board computer (with the 5/16” terminal) connects to the negative (B-) terminal of the speed
controller and from there to the negative post on battery No. 6. The positive terminal of the charger recepta-
cle is connected to the positive post of battery No. 1. The grey wire (sense lead) from the charger receptacle
is connected to the sense lead fuse, which is connected to the grey wire from the on-board computer. If the
charger works with one vehicle, but does not work with another, then it can be assumed that the problem is
in the charger circuit of the vehicle. Check the connections between the No. 10 grey wire from the charger
receptacle, the sense lead fuse, and the No. 18 grey wire from the on-board computer. Also check connec-
tions of the fuse link assembly located on the charger receptacle (Figure 19-2, Page 19-3).
19-2
WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER. CONSULT
YOUR CLUB CAR DISTRIBUTOR/DEALER.
• DO NOT USE OR SERVICE THE CHARGER NEAR WATER.
• ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHILE SERVICING VEHICLE
OR CHARGER.
• TURN KEY SWITCH OFF AND PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL
POSITION PRIOR TO SERVICING THE CAR.
• TO AVOID UNINTENTIONAL STARTING OF THE CAR, DISCONNECT THE BATTERIES AND
THEN DISCHARGE THE CONTROLLER AS FOLLOWS:
- TURN THE KEY SWITCH TO “ON” AND PLACE THE FORWARD AND REVERSE LEVER IN
THE REVERSE POSITION .
- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.