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Manual Number 103373121

Edition Code 0408D1010C

Domestic PowerDrive, IQ Plus and 

High Frequency Battery Chargers

2008-2011 Domestic 

Battery Charger

Maintenance and Service 

Manual

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Summary of Contents for 2008-2011

Page 1: ... AR E CH AR GE D CO NN EC T DC PL UG TO RE CE PT AC LE CH AR GE R W ILL ST AR T AU TO MA TI CA LL Y IN 2 TO 10 SE CO ND S 4 3 1 2 CO NN EC T AC SU PP LY CO RD TO A PR OP ER LY GR OU ND ED TH RE E W IR E OU TL ET OF TH E PR OP ER VO LT AG E AN D FR EQ UE NC Y AS SH OW N ON CH AR GE R OU TP UT LE AD PO LA RIT Y PO SI TI VE RE D NE GA TI VE BL AC K SE NS E BL UE M OD EL 26 56 0 AC IN PU T 12 0V 9 5 A...

Page 2: ......

Page 3: ...lub Car distributor dealer representative or by a Club Car factory trained technician It is the policy of Club Car LLC 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 servic...

Page 4: ...r improve our vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car dealers and will when applicable appear in future editions of this manual Club Car LLC reserves the right to change specifications and designs at any time without notice and without the obligation ...

Page 5: ...RGER EXTERNAL General Information 3 1 PowerDrive External Charger Features 3 2 Battery Warning Light 3 2 The Charge Circuit 3 3 DS DS Villager 4 800 810 and 850 3 3 Turf 1 and Carryall 1 3 4 Precedent 4 x 12 Volt 3 5 Precedent 6 x 8 Volt 3 6 Charger Installation and Operation 3 8 AC Power Connection 3 9 Charging Batteries 3 9 Testing Charger Operation 3 11 DC Cord and Plug Inspection 3 11 Checking...

Page 6: ... 1 PowerDrive Onboard Charger Features 4 2 Battery Warning Light 4 2 The Charge Circuit 4 2 Charger Operation 4 4 Checking Battery Condition 4 6 Troubleshooting 4 7 Test Procedures 4 9 Index of Test Procedures 4 9 Charger Repairs 4 24 DC Cord 4 24 Heatsink 4 25 Transformer 4 26 Ammeter 4 27 Fuse Link 4 28 Charger Relay 4 28 Charger AC Circuit Breaker 4 29 Charger AC Cord and Retractable Cord Reel ...

Page 7: ...Charge Cycle 5 9 Troubleshooting 5 9 Test Procedures 5 12 Index of Test Procedures 5 12 Charger Repairs 5 23 DC Cord 5 23 Rectifier 5 24 Transformer 5 25 Ammeter 5 26 Fuse Link 5 27 Voltage Suppressor 5 28 Charger Relay 5 28 Charger AC Circuit Breaker 5 28 Charger AC Cord 5 29 Charging a Battery Pack that has Low Voltage 5 29 SECTION 6 POWERDRIVE 3 MODEL 26560 General Information 6 1 PowerDrive 3 ...

Page 8: ...rd 6 32 Charging a Battery Pack that has Low Voltage 6 34 SECTION 7 POWERDRIVE 3 MODEL 26580 General Information 7 1 PowerDrive 3 Battery Charger Features 7 2 Battery Warning Light 7 2 The Charge Circuit 7 3 DS 800 810 and 850 Vehicles 4 x 12 Volt 7 3 Turf 1 and Carryall 1 Vehicles 6 x 8 Volt 7 4 Precedent Vehicles 4 x 12 Volt 7 5 Precedent Vehicles 6 x 8 Volt 7 6 Charger Installation and Operatio...

Page 9: ... 8 2 UL and CSA Listing 8 2 The Charge Circuit 8 3 External Charger Installation and Operation 8 4 External Charger AC Power Connection 8 5 Charging Batteries 8 5 External Charger Plug and Receptacle 8 7 Checking Battery Condition with an External Charger 8 8 Start Charge Cycle 8 8 Testing Charger Operation 8 8 Troubleshooting 8 9 Test Procedures 8 12 Index of Test Procedures 8 12 Charger Repairs ...

Page 10: ...s 9 9 Index of Test Procedures 9 9 Charger Repairs 9 22 DC Cord 9 22 Heatsink 9 23 Transformer 9 24 Ammeter 9 24 Fuse Link 9 26 Charger Relay 9 26 Charger AC Circuit Breaker 9 27 Charger AC Cord and Retractable Cord Reel 9 27 Retractable AC Cord Reel 9 28 Charging a Battery Pack that has Low Voltage 9 29 Onboard Charger Removal and Installation 9 31 SECTION 10 HIGH FREQUENCY CHARGER ONBOARD Genera...

Page 11: ...0 9 Test Procedures 10 10 Index of Test Procedures 10 10 Battery Troubleshooting Examples 12 Volt Batteries 10 19 Battery Troubleshooting Examples 8 Volt Batteries 10 20 Battery Troubleshooting Examples 6 Volt Batteries 10 21 Charger Repairs 10 22 Onboard Charger Removal and Installation 10 22 SECTION i INDEX ...

Page 12: ...Page x 2008 2011 Domestic Battery Charger Maintenance and Service Manual ...

Page 13: ... could result in minor personal injury or product or property damage CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNING The following safety statements must be heeded whenever the vehicle or battery charger is being operated repaired or serviced Service technicians should become familiar with these gene...

Page 14: ...ion to avoid shorting of components or wiring For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear F...

Page 15: ...rty damage personal injury or death Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or...

Page 16: ...from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order Figure 1 3 Precedent Battery Configuration Style C 6 x 8 Volt Batteries Figure 1 4 DS DS Villager 4 800 810 850 and Carry all 232 IQ System 4x12 volt Battery Configuration Viewed from driv...

Page 17: ...battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order Figure 1 7 Transporter 4 and 6 IQ Plus and Carryall 6 Style A IQ Plus Battery Configuration Figure 1 8 Villager 6 and 8 IQ Plus Battery Configuration Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables 2 Remove negativ...

Page 18: ...1 ...

Page 19: ...rDrive external 17930 11 101802201 17930 18 101802202 17930 19 101802203 Section 3 PowerDrive Charger External PowerDrive onboard 17935 10 101814301 17935 20 101814303 17935 30 101814304 17935 40 102546901 Section 4 PowerDrive Charger Onboard PowerDrive2 22110 11 101802204 22110 18 101802205 22110 19 101802206 Section 5 PowerDrive 2 Charger External PowerDrive3 26560 11 103394401 26560 18 10339440...

Page 20: ... charge cycle 48 48 48 DC current amps start of charge cycle 17 17 17 DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle 3 5 3 5 3 5 Dimensions Weight Case overall length 10 25 in 26 cm 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 8 687 in 22 1 cm Case overall height 9 0 in 22 9 cm 9 0 in 22 9 cm 9 0 in 22 9 cm AC cord length 74 in...

Page 21: ...8 48 48 DC current amps start of charge cycle 13 13 13 DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle 3 5 3 5 3 5 Dimensions Weight Case overall length 6 5 in 16 5 cm 6 5 in 16 5 cm 6 5 in 16 5 cm Case overall width 7 75 in 19 7 cm 7 75 in 19 7 cm 7 75 in 19 7 cm Case overall height 7 785 in 19 8 cm 7 785 in 19 8 cm 7 785 in 19 8 cm AC cord length 74 in 188 cm 108 ...

Page 22: ...e watts 1140 1140 1140 DC OUTPUT DC voltage start of charge cycle 48 48 48 DC current start of charge cycle 14 5 14 5 14 5 DC voltage end of charge cycle 60 60 60 DC current amps end of charge cycle 4 5 4 5 4 5 DIMENSIONS WEIGHT Case overall depth 7 8 in 19 8 cm 7 8 in 19 8 cm 7 8 in 19 8 cm Case overall width 7 13 in 18 1 cm 7 13 in 18 1 cm 7 13 in 18 1 cm Case overall height 9 75 in 24 8 cm 9 75...

Page 23: ... watts 1140 1140 1140 DC OUTPUT DC voltage start of charge cycle 48 48 48 DC current start of charge cycle 14 5 14 5 14 5 DC voltage end of charge cycle 60 60 60 DC current amps end of charge cycle 4 5 4 5 4 5 DIMENSIONS WEIGHT Case overall depth 7 8 in 19 8 cm 7 8 in 19 8 cm 7 8 in 19 8 cm Case overall width 7 13 in 18 1 cm 7 13 in 18 1 cm 7 13 in 18 1 cm Case overall height 9 75 in 24 8 cm 9 75 ...

Page 24: ...t of charge cycle 17 17 17 17 DC voltage VDC end of charge cycle 60 60 60 60 DC current amps end of charge cycle 3 5 3 5 3 5 3 5 Dimensions Weight Case overall length 10 25 in 26 cm 10 25 in 26 cm 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 8 687 in 22 1 cm 8 687 in 22 1 cm Case overall height 9 437 in 24 cm 9 437 in 24 cm 9 437 in 24 cm 9 437 in 24 cm AC cor...

Page 25: ...ent amps start of charge cycle 17 17 17 DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle 4 7 4 7 4 7 Dimensions Weight Case overall length 10 25 in 26 cm 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 8 687 in 22 1 cm Case overall height 9 0 in 22 9 cm 9 0 in 22 9 cm 9 0 in 22 9 cm AC cord length 74 in 188 cm 108 in 274 3 cm 108 in...

Page 26: ... 0 13 0 DC output DC voltage VDC start of charge cycle 48 48 DC current amps start of charge cycle 17 17 DC voltage VDC end of charge cycle 60 60 DC current amps end of charge cycle 4 7 4 7 Dimensions Weight Case overall length 10 25 in 26 cm 10 25 in 26 cm Case overall width 7 25 in 18 4 cm 7 25 in 18 4 cm Case overall height 9 5 in 24 1 cm 9 5 in 24 1 cm AC cord length 17 ft 5 2 m retractable 17...

Page 27: ...C voltage nominal 120 VAC 230 VAC Frequency 45 65 Hz AC Power Factor nominal 0 99 120 VAC 0 98 230 VAC Power consumption AC current amps Max 12 Amps Nominal 9 5 Amps rms 120 VAC 5 Amps rms 230 VAC DC output DC voltage VDC nominal 48 V DC voltage VDC maximum 68 V DC current maximum 18 Amps Interlock current maximum 1 Amp Dimensions Weight Case overall length 11 in 28 cm Case overall width 9 7 in 24...

Page 28: ...2 ...

Page 29: ...ntified 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 NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will ...

Page 30: ...uring storage BATTERY WARNING LIGHT IQ System and Excel System vehicles feature a dash mounted battery warning light above the steering col umn that 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 onboard computer When the batteries receive an incomplete charge because 1 ...

Page 31: ...arger receptacle is connected to the pos itive 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge...

Page 32: ... connected to the pos itive 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the...

Page 33: ...puter and connects to the negative post of battery no 4 The positive terminal of the charger recepta cle is connected to the positive post of battery no 1 The gray wire from the onboard computer is con nected to the charger receptacle 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 ...

Page 34: ... post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the charger recepta cle 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 re...

Page 35: ... 7 3 Figure 3 6 Charge Circuit and Style C Battery Configuration 6 x 8 Volt Precedent Vehicles S1 S2 B M B 1 2 4 3 6 5 10 BLACK 6 RED 6 BLACK 6 BLACK 6 BLACK BATTERY BANK 10 BLACK 10 RED 10 RED 18 GRAY ONBOARD COMPUTER FRONT OF VEHICLE SINGLE POSITION CONNECTOR CHARGER RECEPTACLE SOLID STATE SPEED CONTROLLER TO SOLENOID ...

Page 36: ...ll result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death 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 Eac...

Page 37: ...uge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Mount charger by setting it on a shelf wall mount with keyhole or hang securely from ceiling by the handle Do not hang charger upside down Ensure that the charger...

Page 38: ...e ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce t...

Page 39: ... 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 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...

Page 40: ...nect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter wil...

Page 41: ...icles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Internal AC breaker Test Procedure 3 AC Power and Continuity Test of AC Circuit on pa...

Page 42: ... page 3 24 Failed transformer Test Procedure 6 Transformer on page 3 22 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 Onboard computer...

Page 43: ... PowerDrive Battery Charger GREEN GROUND WIRE TAN WIRE TO PRIMARY COIL BLACK WIRE TO CIRCUIT BREAKER RED WIRE TO HEATSINK BLUE WIRE TO DC CORD TAN WIRE TO PRIMARY COIL BLACK WIRE TO RELAY RED WIRE OF DC CORD RED WIRE TO RELAY SECONDARY COIL WIRES TAN SECONDARY COIL WIRES BLACK DC CORD BLACK WIRE TO AMMETER PRIMARY COIL SECONDARY COIL ...

Page 44: ...ion that might prevent a sound electrical connection 2 Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 DS DS Villager 4 Turf 1 Carryall 1 800 810 and 850 Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figure...

Page 45: ...voltage 4 1 DS DS Villager 4 800 810 and 850 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 3 12 Page 3 17 4 2 Turf 1 and Carryall 1 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of batt...

Page 46: ...r temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 3 34 Figure 3 14 Battery Voltage Test Style A Battery Configuration Figure 3 15 Battery Voltage Test Style B Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 4 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to ...

Page 47: ...properly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check th...

Page 48: ...tput being low open circuit diode If a diode has failed the entire heatsink must be replaced To check diodes 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect one transformer secondary coil wire from the diode terminal Figure 3 18 Page 3 21 4 Using a low voltage continuity tester or multimeter set to the diode test function co...

Page 49: ...on is made between the charger and the batteries both fuse links will blow when the DC cord is connected to the vehicle whether or not the AC cord is plugged into an outlet 3 On rare occasions both diodes may fail as a result of a lightning strike at the charging location 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...

Page 50: ... circuit test should be done before performing this test procedure to ensure the continuity of the AC cord internal AC circuit breaker and charger wiring See Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 19 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect transformer secondary coil wires 1 and 5 from t...

Page 51: ...bleshooting and repairs are complete properly connect relay wiring See following WARN ING ý 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 TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See addi...

Page 52: ...AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced 7 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug Figure 3 23 Page 3 24 The tester should indicate continuity on only the round pin If any other reading is...

Page 53: ...oils a primary coil and a secondary coil Figure 3 22 Page 3 23 Primary Coil 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect terminals from transformer tan primary coil transformer wires 4 and 6 Figure 3 22 Page 3 23 4 Place the continuity tester probes on the disconnected primary coil transformer wires The tester should indi...

Page 54: ...If tester indicates continuity the relay contacts have failed closed and the relay must be replaced 4 Place continuity test probes on contact terminals of relay With batteries connected insert DC plug into receptacle The tester should indicate continuity If tester does not indicate continuity relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle rece...

Page 55: ... from the vehicle receptacle 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 3 25 Page 3 27 4 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink 5 Remove the wire tie that secures the DC cord wire to the secondary coil wire tan 6 Remo...

Page 56: ...NG ý WARNING 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 7 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in lb 1 2 N m HEATSINK See General Warning Section 1 Page 1 1 See additional WARNING on page...

Page 57: ...nsformer wires from the fuse 8 Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in lb 3 2 N m Figure 3 10 Page 3 15 2 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to ...

Page 58: ...ace the ammeter in position in the charger face Figure 3 26 Page 3 30 2 Install nuts 2 and tighten until ammeter is firmly secured 3 Connect the black wire of the DC cord 5 to the left as viewed from inside the charger post of the amme ter 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 5 Thread nuts 4 onto both posts of...

Page 59: ...2 5 N m 4 Install the charger cover VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 The voltage suppressor which is incorporated into a wire assembly in the charger protects the onboard com puter by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnec...

Page 60: ... Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the two black wires attached to the AC circuit breaker Figure 3 27 Page 3 33 4 With a pair of pliers squeeze in the retaining tabs on the sides of the AC circuit breaker and remove the circuit breaker through the mounting hole in the face of the charger AC Circuit Breaker Instal...

Page 61: ...een wire to the charger base Tighten the screw on the green ground wire terminal to 18 in lb 2 0 N m 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 Figure 3 27 Charger Relay GREEN GROUND WIRE TAN WIRE TO PRIMARY COIL WHITE WIRE FROM AC CORD STRAIN RELIEF BUSHING ...

Page 62: ...OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 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 tan wire 4 f...

Page 63: ...er and connect it to the relay Connect the short black wire 3 from the relay to the AC circuit breaker Figure 3 28 Page 3 34 See following WARN ING ý 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 9 Install the charger cover and the...

Page 64: ...3 ...

Page 65: ...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 The PowerDrive battery charger is automatic and has no external controls Figure 4 1 Page 4 1 When the AC cord is plugged in there is a 2 to 15 second delay before charging begins The onboard computer OBC records the amount of energy consumed as the ...

Page 66: ...es and will com plete the charge during the next charge cycle When the charger AC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds 25 seconds for Precedent vehicles if the charge is less than 90 complete but the vehicle has enough power for 60 minutes of operation This will alert the opera tor that the vehicle may be used but t...

Page 67: ...s two wires in the adapter harness One wire connects to the onboard computer The second wire connects to the charger receptacle gray lead wire To check the charge circuit check the connections between the 18 gauge gray wire from the OBC the sense lead fuse DC cord red wire DC cord black wire and the wire connections between the batteries Figure 4 2 Charge Circuit DS Villager 4 Figure 4 3 Charge Ci...

Page 68: ... Make sure it is operating properly before putting it back in use Each charger should have its own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result in an electrical...

Page 69: ...voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 Monitor the ammeter Under normal operating conditions when the charger is on and the batteries are discharged the charger will shut off in order to run a self diagnostic program ammeter will drop to zero one hour and two hours into the charge cycle See following CAUTION and NOTE CAUTION Do not c...

Page 70: ...PowerDrive battery charger this practice is not necessary The onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart See Troubleshooting on...

Page 71: ...harger from the vehicle See Onboard Charger Removal on page 4 33 Use the following Troubleshooting Guide for troubleshooting export PowerDrive onboard battery chargers model numbers 17935 10 and 17935 40 The Troubleshooting Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages POWERDRIVE ONBOARD BATTERY CHAR...

Page 72: ... ammeter Replace ammeter Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 4 19 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 4 14 Loose internal fuse connection Tighten connection Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in ...

Page 73: ...ows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 4 19 Failed transformer Test Procedure 6 Transformer on page 4 17 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals AC power interrupted Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 13 Onboard computer malfun...

Page 74: ...e resistance should be less than 2 ohms 2 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 4 5 Page 4 10 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 34 volts DC to allow the onboard computer to clos...

Page 75: ... 11 Figure 4 6 Battery Voltage Test Precedent Style A Battery Configuration Figure 4 7 Battery Voltage Test Precedent Style B Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 4 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 4 Figure 4 8 Battery Voltage Test Precedent Style C Battery Configur...

Page 76: ...ce black probe of multimeter on terminal with blue DC cord wire and red probe to terminal with red relay wire Figure 4 9 Page 4 12 3 Multimeter should indicate full battery voltage approximately 47 50 volts If reading is incorrect replace control board AC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and blue wires remain connected to vehicle Set multimeter to volts AC 2 Disconne...

Page 77: ...age is not present have building wiring checked by a licensed electrical contractor 5 Check continuity of the AC circuit 5 1 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 5 2 Remove the charger cover 5 3 Bypass the relay 5 3 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 bla...

Page 78: ...AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 3 Remove the charger cover 4 Disconnect one transformer secondary coil wire from the diode terminal Figure 4 13 Page 4 15 5 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 pro...

Page 79: ... DC cord black wire should be connected to the left side of the ammeter when viewed from inside the charger Figure 4 4 Page 4 6 If a reverse polarity connection is made between the charger and the batteries both fuse links will blow when the DC cord is connected to the vehicle whether or not the AC cord is plugged into an outlet 3 Make sure the charger is wired to the vehicle correctly the DC cord...

Page 80: ...probes and check the DC cord again Figure 4 20 Page 4 21 The circuit should show continuity in only one direction 8 If the circuit does not show continuity in either direction and the charger fuse is not blown individually check all connections and the continuity of the DC cord and ammeter See Test Procedure 8 Conti nuity on page 4 19 Also check the diodes heatsink See Test Procedure 4 Diodes on p...

Page 81: ...Check continuity between the DC cord red black and blue wires Figure 4 4 Page 4 6 There should be no continuity TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns If the transformer has failed the ammeter will indicate low output or no output however the transformer may hum A blown AC line ...

Page 82: ...s normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuity of the DC circuit See Test Procedure 5 Charger DC Circuit Continuity Test on page 4 16 12 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING ý WARNING The relay wiring must be properly connected prior to placing th...

Page 83: ...obtained the short AC cord and retractable cord reel must be tested independently of each other 8 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug on the retractable cord reel Figure 4 18 Page 4 20 The tester should indicate continuity on only the round pin If any other reading is obtained the s...

Page 84: ...ger Maintenance and Service Manual 4 Figure 4 18 AC Cord and Retractable Cord Reel Continuity Test Figure 4 19 Heatshrink Removal 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 200 OHM SETTING 4 C lub C ar ...

Page 85: ...eading is obtained the AC cord and retractable cord reel must be tested independently of each other 11 If the correct readings are obtained in all of the previous steps the short AC cord is functioning properly Proceed to the following test procedure to test the retractable cord reel Retractable Cord Reel Check continuity of the AC cord and retractable cord reel at the same time 1 Disconnect the A...

Page 86: ... 33 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 4 22 Page 4 24 4 Disconnect the red wire of the DC cord from the heatsink 5 Disconnect the blue wire from the control board 6 Using a multimeter set for 200 ohms place the red probe on the red wire of the DC cord Test for con tinuity on each of the wires on the o...

Page 87: ...ch of the secondary coil wires tan The tester should indicate continuity between the buss bar and both of the 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 Relay 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Rem...

Page 88: ...moval 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 4 33 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 4 23 Page 4 24 4 Remove nut attaching the red wire 6 of ...

Page 89: ...7 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in lb 1 2 N m HEATSINK Heatsink Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 33 See preceding WARNING 2 Remove the charger cover 3 Remove both secondary coil transformer wires tan from the heatsink Fig...

Page 90: ...ar of the charger case Tighten the four bolts and nuts to 28 in lb 3 2 N m Figure 4 4 Page 4 6 2 Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in lb 2 0 N m 3 Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in lb 2 0 N m 4 Connect one secondary coil transformer wire blac...

Page 91: ...ace 5 Remove the ammeter from the face of the charger Ammeter Installation 1 Place the ammeter in position in the charger face Figure 4 24 Page 4 27 2 Install nuts 2 and tighten until ammeter is firmly secured 3 Connect the black wire of the DC cord 5 to the left as viewed from inside the charger post of the amme ter 4 Connect the buss bar 3 from the fuse link to the right post of the ammeter Plac...

Page 92: ...viewed from the front of the charger 2 Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 4 24 Page 4 27 Tighten to 22 in lb 2 5 N m 3 Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tighten to 22 i...

Page 93: ...the circuit breaker through the mounting hole in the face of the charger AC Circuit Breaker Installation Install in reverse order of removal CHARGER AC CORD AND RETRACTABLE CORD REEL See General Warning Section 1 Page 1 1 Short AC Cord Removal 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 4 33 See WARN...

Page 94: ... 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 and install the charger in the vehicle See Onboard Charger Installation on page 4 34 6 Check charger for proper operation RETRACTABLE AC CORD REEL See General Warning Section 1 Page 1 1 Retractable AC Cord Reel Removal 1 Disco...

Page 95: ... 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 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 5 Install the charger cover and install the charger in the vehicle See Onboard Charg...

Page 96: ...e test the batteries again If the battery pack voltage is above 32 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual Figure 4 26 PowerDrive Onboard Charger Wiring Diagram Relay Bypassed BLACK BLAC...

Page 97: ...page 4 33 DS VILLAGER 4 Onboard Charger Removal 1 Connect the batteries See Connecting The Batteries on page 1 4 2 Remove four bolts 21 flat washers 22 lock washers 23 and nuts 24 from charger mounting brack ets Figure 4 27 Page 4 33 3 Remove 10 gauge black charger DC cord wire 19 from the charger receptacle fuse link Figure 4 28 Page 4 34 4 Remove 10 gauge red charger DC cord wire from the positi...

Page 98: ...ck washers 23 and nuts 24 securing charger to chassis and tighten to 108 in lb 12 N m Figure 4 27 Page 4 33 4 Connect the batteries See Connecting The Batteries on page 1 4 PRECEDENT VEHICLES Onboard Charger Removal 1 Connect the batteries See Connecting The Batteries on page 1 4 2 Disconnect the charger DC cord at the three pin connector 1 Figure 4 29 Page 4 35 3 Remove four bolts 2 flat washers ...

Page 99: ...ice Manual Page 4 35 4 Onboard Charger Installation 1 Installation is reverse of removal 2 Install four bolts 2 and nuts 5 securing charger to chassis and tighten to 108 in lb 12 N m 3 Connect the batteries See Connecting The Batteries on page 1 4 Figure 4 29 Onboard Charger Mounting Precedent Vehicles C lu b C ar 5 4 3 2 1 ...

Page 100: ...4 ...

Page 101: ... dealer or distributor The PowerDrive 2 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 NOTE All vehicles except Precedent Shortly after charging begins the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ...

Page 102: ... dash mounted warning light above the steering column that 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 onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automatic charger...

Page 103: ...arger 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse on all vehicles except Precedent vehicles an...

Page 104: ...hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion Figure 5 3 Charge Circuit and Battery Configuration Precedent Veh...

Page 105: ...ach charger should have its own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result in an electrical shock Do not use an adapter to plug charger into a two blade outle...

Page 106: ... there is adequate ventilation CHARGING BATTERIES ý WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Be sure the fuse link is clean and tight not applicable to Precedent vehicles Be sure all wire connections at the receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug s...

Page 107: ...state and the vehicle has not been driven the onboard com puter will not perform the self diagnostic test Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold ...

Page 108: ...s 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 D...

Page 109: ...charge cycle should be approximately 59 to 63 volts 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 NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the la...

Page 110: ...and DC Plug and Receptacle on page 5 13 Receptacle fuse link is blown not applicable to Precedent vehicles See Section 12 Electrical Components in the appropriate maintenance and service manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter doe...

Page 111: ...8 Continuity on page 5 20 Failed transformer Test Procedure 6 Transformer on page 5 18 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 15 O...

Page 112: ...d DC Plug and Receptacle 2 Onboard Computer 3 AC Power and Continuity Test of AC Circuit 4 Rectifier 5 Charger DC Circuit Continuity Test 6 Transformer 7 Battery State of Charge Test 8 Continuity Figure 5 7 PowerDrive 2 Battery Charger SECONDARY COIL WIRES TAN AND BLACK DC CORD RED WIRE TO AMMETER SECONDARY COIL PRIMARY COIL GREEN GROUND WIRE WHITE WIRE TO PRIMARY COIL BLACK WIRE TO CIRCUIT BREAKE...

Page 113: ...ptacle is connected to the positive post of battery no 1 Figure 5 2 Page 5 3 Precedent vehicles Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figure 5 3 Page 5 4 DS vehicles only 3 1 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 13 3 2 Check the connection...

Page 114: ...ing a Battery Pack that has Low Voltage on page 5 29 Precedent vehicles only 5 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 5 10 Page 5 14 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC...

Page 115: ...operly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the ...

Page 116: ...t in property damage severe personal injury or death TEST PROCEDURE 4 RECTIFIER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 The rectifier converts the AC voltage from the transformer secondary coil to DC voltage This conversion is necessary since the batteries require DC voltage for charging A failed or improperly wired rectifier could result in little or no battery c...

Page 117: ...e 5 13 Page 5 16 The multimeter should indicate an overload no continuity for all three of the reaming rectifier terminals If any other reading is indicated the rectifier has failed and must be replaced 6 On rare occasions the rectifier may fail as a result of a lightning strike at the charging location 7 Ensure that the charger is wired properly and all connections are clean and tight See followi...

Page 118: ...sformer may be caused by aging or a short circuit in adjacent coil turns If the transformer has failed the ammeter will indicate low output or no output however the transformer may hum A blown AC line fuse or tripped AC circuit breaker in the charger or the storage facility may be caused by an improperly wired charger or a failed transformer An AC circuit test should be done before performing this...

Page 119: ...sured voltage is approximately 42 5 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced Figure 5 16 Page 5 19 10 If the voltage reading is normal 43 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuity of the DC circuit See Test Procedure 5 Charger DC Circuit Continuity Test on pag...

Page 120: ...nual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Fuse 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord black wire from the fuse and position it so it does not touch any metal part of the charger Figure 5 18 Page 5 24 4 Using a multimeter set for 200 ohms pl...

Page 121: ...the DC cord disconnect the black wire of the DC cord from the fuse Figure 5 18 Page 5 24 4 Disconnect the red wire of the DC cord from the ammeter 5 Disconnect the blue wire from the blue wire assembly that connects to the charger relay 6 Place the clip of the continuity tester on the red wire of the DC cord 7 Place the continuity test probe on the positive pin of the DC plug positive and negative...

Page 122: ...the diode test function ç place the black probe of the multimeter on the sense lead pin short pin of the DC plug Place the red probe on the positive pin of the DC plug The multimeter should indicate no tone If a tone is emitted indicating a closed circuit then the voltage suppressor has failed and should be replaced See following NOTE NOTE All vehicles except Precedent Repeated failure of sense le...

Page 123: ...place the AC circuit breaker CHARGER REPAIRS See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 ý WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 5 6 Page 5 8 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD ...

Page 124: ...perly route and secure wiring could result in charger malfunction property damage or severe personal injury 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in lb 1 2 N m RECTIFIER Rectifier Removal 1 Disconnect AC cord from the wa...

Page 125: ...er Figure 5 6 Page 5 8 See following NOTE NOTE The positive terminal of the rectifier is marked on the edge of the rectifier case The positive ter minal can also be identified by its orientation and the notch in the rectifier case 5 Connect the two black transformer secondary coil wires to the AC terminals on the rectifier 6 Connect the black wire from the charger fuse to the negative rectifier te...

Page 126: ...rd white wire 5 Connect the AC cord white wire to the tan primary coil wire Figure 5 17 Page 5 20 6 Slide the heatshrink tubing over the connection and apply heat to the heatshrink to insulate the connec tion between the AC cord white wire and the tan primary coil wire See following WARNING ý WARNING Make sure the electrical connections are properly insulated Failure to properly insulate electrica...

Page 127: ...moval 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Gently press the fuse toward the transformer to remove the fuse from the mounting tab 4 Remove the two nuts securing the two black wires to the fuse terminals and remove the fuse Fuse Link Installation 1 Connect the short black wire from the rectifier to one of the fuse terminal pos...

Page 128: ...harger Voltage Suppressor Installation 1 Install in reverse order of removal See following NOTE NOTE The charger relay blade connector is located off center within the relay housing When connecting voltage suppressor slip on connector to relay blade connector make sure slip on connector is positioned so that flat side of connector is closest to relay housing CHARGER RELAY See General Warning Secti...

Page 129: ... Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face 2 Connect the AC cord black wire to the AC circuit breaker 3 Place a piece of heatshrink tubing over the AC cord white wire 4 Connect the AC cord white wire to the tan primary coil wire Figure 5 17 Page 5 20 5 Slide the heatshrink tubing over the connection and apply heat to the heatshr...

Page 130: ...6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING ý 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 7 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the ...

Page 131: ...r Wiring Diagram Relay Bypassed BLACK DISCONNECTED FROM RELAY AND CONNECTED TO BREAKER BLACK DISCONNECTED 4 3 DC CORD RED RED BLUE BLUE WHITE BLACK BLACK BLACK AC CIRCUIT BREAKER AC INPUT PLUG AC CORD GREEN CASE GROUND WHITE TAN TAN BLACK TAN BLACK AMMETER TRANSFORMER RELAY PRIMARY COIL SECONDARY COIL RED FUSE RED WHITE WHITE BLACK TAN BLACK VOLTAGE SUPPRESSOR RECTIFIER 4 1 5 6 AC AC ...

Page 132: ...5 ...

Page 133: ... exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies Figure 6 1 PowerDrive 3 Battery Charger AF TE R CH AR GER TU RN S OFF DI SC ONN EC T DC PL UG BY GRA...

Page 134: ...ng storage BATTERY WARNING LIGHT IQ System and Excel System vehicles feature a dash mounted battery warning light above the steering col umn that 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 onboard computer When the batteries receive an incomplete charge because 1 the...

Page 135: ...rger receptacle is connected to the pos itive 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge ...

Page 136: ...onnected to the pos itive 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the c...

Page 137: ...computer and connects to the negative post of battery no 4 The positive terminal of the charger recepta cle is connected to the positive post of battery no 1 The gray wire from the onboard computer is con nected to the charger receptacle 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 a...

Page 138: ...ive post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the charger recepta cle 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...

Page 139: ... 6 Figure 6 6 Charge Circuit and Style C Battery Configuration 6 x 8 Volt Precedent Vehicles S1 S2 B M B 1 2 4 3 6 5 10 BLACK 6 RED 6 BLACK 6 BLACK 6 BLACK BATTERY BANK 10 BLACK 10 RED 10 RED 18 GRAY ONBOARD COMPUTER FRONT OF VEHICLE SINGLE POSITION CONNECTOR CHARGER RECEPTACLE SOLID STATE SPEED CONTROLLER TO SOLENOID ...

Page 140: ...l result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death 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 Each...

Page 141: ...heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 meters Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Mount charger by setting it on a shelf wall mount with keyhole or hang securely from ceiling by the handle Do not hang charger upside down Ensure that the charger...

Page 142: ...e receptacle Figure 6 7 Page 6 9 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial char...

Page 143: ...y as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 6 3 Page 6 4 and that the internal charger wiring is correct Figure 6 9 Page 6 11 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 o...

Page 144: ...ycle should be approximately 59 to 63 volts 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 NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charg...

Page 145: ... page 6 16 Receptacle fuse link is blown not applicable to Precedent vehicles See Electrical Components section in the appropriate maintenance and service manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet vo...

Page 146: ...3 Failed transformer Test Procedure 6 Transformer on page 6 22 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 6 19 Onboard computer malfunct...

Page 147: ...re 6 10 PowerDrive 3 Battery Charger Components Model 26560 SECONDARY COIL WIRES TAN AND BLACK AC CORD SECONDARY COIL PRIMARY COIL FUSE LINK DC CORD RED WIRE TO AMMETER DC CORD BLUE WIRE TO RELAY DC CORD BLACK WIRE TO FUSE GREEN GROUND WIRE WHITE WIRE TO PRIMARY COIL BLACK WIRE TO CIRCUIT BREAKER BLACK WIRE TO PRIMARY COIL ...

Page 148: ...r any condition that might prevent a sound electrical connection 2 Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 DS DS Villager 4 Turf 1 Carryall 1 800 810 and 850 Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery...

Page 149: ...er 4 800 810 and 850 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 6 12 Page 6 17 4 2 Turf 1 and Carryall 1 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 6 13 Pag...

Page 150: ...pass the charger relay See Charging a Battery Pack that has Low Voltage on page 6 34 Figure 6 14 Battery Voltage Test Precedent Style A Battery Configuration Figure 6 15 Battery Voltage Test Precedent Style B Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 4 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe...

Page 151: ...orms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit bre...

Page 152: ...E This Powerdrive 3 Model 26560 uses a rectifier mounted to an aluminum heat sink plate A running change replaced the rectifier with two diode heatsink assemblies The model number changed to 26580 See Section 7 PowerDrive 3 Model 26580 The rectifier converts the AC voltage from the transformer secondary coil to DC voltage This conversion is necessary since the batteries require DC voltage for char...

Page 153: ...19 Page 6 20 The multimeter should indicate an overload no continuity for all three of the remaining rectifier terminals If any other reading is indicated the rec tifier has failed and must be replaced 6 On rare occasions the rectifier may fail as a result of a lightning strike at the charging location 7 Ensure that the charger is wired properly and all connections are clean and tight See followin...

Page 154: ...ircuit in adjacent coil turns If the transformer has failed the ammeter will indicate low output or no output however the transformer may hum A blown AC line fuse or tripped AC circuit breaker in the charger or the storage facility may be caused by an improperly wired charger or a failed transformer An AC circuit test should be done before performing this test procedure to ensure the continuity of...

Page 155: ... 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 TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and then reconnect it...

Page 156: ...n of the AC plug 6 The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced 8 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug 6 Figure 6 22 Page 6 24 The tester should indi cate continuity on only the round pin If any ot...

Page 157: ...ked middle pin of the DC plug The tester should indicate no continuity If tester indicates continuity the DC cord must be replaced 13 Move continuity test probe to the blue wire of the DC cord Check for continuity at the middle pin The tester should indicate continuity If tester does not indicate continuity replace DC cord Transformer The PowerDrive 3 battery charger transformer has two sets of co...

Page 158: ... 3 0 and 4 0 onboard computers will quickly flash the battery warning light on the dash to indicate a problem with the voltage supressor Relay 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove black wires 3 and 4 from contact terminals of the relay Figure 6 9 Page 6 11 Place conti nuity test probes on contact terminals of the rela...

Page 159: ...r supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove the DC cord black wire from the fuse by loosening the nut on the fuse Figure 6 23 Page 6 27 4 Remove the DC cord red wire from the ammeter 5 Remove the DC cord blue wire f...

Page 160: ...g pliers put the strain relief bushing on the cord and insert it into the charger base 6 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in lb 1 2 N m RECTIFIER NOTE This Powerdrive 3 Model 26560 uses a rectifier mounted to an aluminum heat sink plate A running change replaced the rectifier with two diode heatsink assemblie...

Page 161: ...ORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 Transformer Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the black primary coil wire 5 from the charger relay Figure 6 22 Page 6 24 4 Carefully cut the heatshrink 7 that insulates the AC cord white wire 4 where it connects to the tan p...

Page 162: ...ction property damage or severe personal injury 8 Install the charger cover and check charger for proper operation AMMETER See General Warning Section 1 Page 1 1 See additional WARNING on page 6 1 Ammeter Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the DC cord red wire 1 and the white wires 2 and 3 from the ammet...

Page 163: ... to remove the fuse from the mounting tab 4 Remove the two nuts securing the two wires to the fuse terminals and remove the fuse Fuse Link Installation 1 Connect the short brown wire from the rectifier to one of the fuse terminal posts and install the nut Tighten nut to 23 in lb 2 6 N m 2 Connect the DC cord black wire to the other fuse terminal post and install the nut Tighten nut to 23 in lb 2 6...

Page 164: ...cle 2 Remove the charger cover 3 Disconnect the two black wires attached to the circuit breaker Figure 6 9 Page 6 11 4 With a pair of pliers squeeze in the retaining tabs on the sides of the circuit breaker and push the circuit breaker through the mounting hole in the face of the charger to remove AC Circuit Breaker Installation Install in reverse order of removal CHARGER AC CORD See General Warni...

Page 165: ...age 6 24 5 Slide the heatshrink tubing 7 over the connection and apply heat to the heatshrink to insulate the con nection between the AC cord white wire 4 and the tan primary coil wire See following WARNING ý WARNING Make sure the electrical connections are properly insulated Failure to properly insulate electrical connections in the charger could result in a short circuit 6 Connect the green wire...

Page 166: ...om the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 6 26 Page 6 35 See following DANGER 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 5 Plug the DC cord into the charger receptacle first and then plug the AC cord...

Page 167: ...tery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual Figure 6 26 PowerDrive 3 Charger Wiring Diagram Relay Bypassed DC CORD RED BLUE BROWN BLACK AC CIRCUIT BREAKER AC CO...

Page 168: ...6 ...

Page 169: ... exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies Figure 7 1 PowerDrive 3 Battery Charger AF TE R CH AR GER TU RN S OFF DI SC ONN EC T DC PL UG BY GRA...

Page 170: ...ng storage BATTERY WARNING LIGHT IQ System and Excel System vehicles feature a dash mounted battery warning light above the steering col umn that 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 onboard computer When the batteries receive an incomplete charge because 1 the...

Page 171: ...rger receptacle is connected to the pos itive 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge ...

Page 172: ...onnected to the pos itive 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the c...

Page 173: ...computer and connects to the negative post of battery no 4 The positive terminal of the charger recepta cle is connected to the positive post of battery no 1 The gray wire from the onboard computer is con nected to the charger receptacle 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 a...

Page 174: ...ive post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the charger recepta cle 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...

Page 175: ... 7 Figure 7 6 Charge Circuit and Style C Battery Configuration 6 x 8 Volt Precedent Vehicles S1 S2 B M B 1 2 4 3 6 5 10 BLACK 6 RED 6 BLACK 6 BLACK 6 BLACK BATTERY BANK 10 BLACK 10 RED 10 RED 18 GRAY ONBOARD COMPUTER FRONT OF VEHICLE SINGLE POSITION CONNECTOR CHARGER RECEPTACLE SOLID STATE SPEED CONTROLLER TO SOLENOID ...

Page 176: ...l result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death 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 Each...

Page 177: ...heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 meters Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Mount charger by setting it on a shelf wall mount with keyhole or hang securely from ceiling by the handle Do not hang charger upside down Ensure that the charger...

Page 178: ...r the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages redu...

Page 179: ...rnal charger wiring is correct Figure 7 9 Page 7 11 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...

Page 180: ...ycle should be approximately 59 to 63 volts 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 NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charg...

Page 181: ...cle on page 7 16 Receptacle fuse link is blown not applicable to Precedent vehicles See Electrical Components section in the appropriate maintenance and service manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC out...

Page 182: ...ailed transformer Test Procedure 6 Transformer on page 7 23 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 7 19 Onboard computer malfunction...

Page 183: ... Charger Components Model 26580 SECONDARY COIL WIRES ORANGE AND PURPLE AC CORD SECONDARY COIL PRIMARY COIL FUSE LINK DIODES HEATSINK DC CORD RED WIRE TO AMMETER DC CORD BLUE WIRE TO RELAY DC CORD BLACK WIRE TO FUSE GREEN GROUND WIRE WHITE WIRE TO PRIMARY COIL BLACK WIRE TO CIRCUIT BREAKER CIRCUIT BREAKER BLACK WIRE TO PRIMARY COIL RELAY BOARD AMMETER ...

Page 184: ... dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 DS vehicles Verify that the 10 gauge red wire from the charger receptacle is connected to the pos itive post of battery no 1 Figure 7 3 Page...

Page 185: ...er 4 800 810 and 850 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 7 12 Page 7 17 4 2 Turf 1 and Carryall 1 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 6 Figure 7 13 Pag...

Page 186: ...pass the charger relay See Charging a Battery Pack that has Low Voltage on page 7 34 Figure 7 14 Battery Voltage Test Precedent Style A Battery Configuration Figure 7 15 Battery Voltage Test Precedent Style B Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 4 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe...

Page 187: ...orms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the AC line fuse or circuit bre...

Page 188: ...NG on page 7 1 A single diode failure is indicated by the failure of one fuse link closed circuit diode or by the charger output being low open circuit diode If a diode has failed the entire diode heatsink must be replaced To check diodes 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect one transformer secondary coil wire ora...

Page 189: ...e should be connected to the relay coil and the DC cord black wire should be connected to the fuse link Figure 7 9 Page 7 11 If a reverse polarity connection is made between the charger and the batteries the fuse link will blow when the DC cord is connected to the vehicle whether or not the AC cord is plugged into an outlet 3 On rare occasions both diodes may fail as a result of a lightning strike...

Page 190: ...See Test Procedure 4 Diodes on page 7 20 6 If the multimeter indicates a voltage reading in both directions a short circuit exists in the charger DC cir cuit usually caused by failed diodes See Test Procedure 4 Diodes on page 7 20 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 7 24 Figure 7 20 DC Plug Test Figure 7 21 DC Plug Test Probes Rev...

Page 191: ...y wire or component in the battery charger while AC power is present Failure to heed this warning will result in an electric shock 5 Make sure the secondary coil wires are not touching one another With the relay bypassed insert the AC plug into an outlet If the AC line fuse blows or AC circuit breaker trips the transformer is shorted inter nally and must be replaced 6 If the AC line fuse does not ...

Page 192: ...r does not indicate continuity then the fuse has failed and must be replaced AC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 7 22 Page 7 25 4 Disconnect the black wire 1 of AC cord from charger AC circuit brea...

Page 193: ...ter indicates continuity the DC cord must be replaced 9 Place the continuity test probe on the unmarked middle pin of the DC plug The tester should indicate no continuity If tester indicates continuity the DC cord must be replaced 10 Move the continuity test probe to the black wire of the DC cord 11 Place the continuity test probe on the negative pin of the DC plug The tester should indicate conti...

Page 194: ...e continuity between the orange and purple wires If tester does not indicate continuity replace the trans former Voltage Suppressor Failed Closed The voltage suppressor which is incorporated into the relay board assembly protects the onboard computer by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is...

Page 195: ...tinuity If tester does not indicate continuity relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the white wire from the left ammeter terminal as viewed from inside the charger 4 Place the continuity tester clip on one of the ammeter posts 5 Place the continuity test probe on the other ammeter po...

Page 196: ...r supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove the DC cord black wire from the fuse by loosening the nut on the fuse Figure 7 23 Page 7 28 4 Remove the DC cord red wire from the ammeter 5 Remove the DC cord blue wire f...

Page 197: ... 26560 See Section 6 PowerDrive 3 Model 26560 Diode Heatsink Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Note wire locations for reassembly and then disconnect the orange and purple secondary coil trans former wires 1 and 2 from the diode heatsink being replaced Figure 7 9 Page 7 11 and Figure 7 10 Page 7 15 4 Remove the wh...

Page 198: ...with primary coil to the rear of the charger case Secure the transformer to the mounting brackets with four screws 2 Connect the orange and purple secondary coil transformer wires 1 and 2 to the diodes at the original locations Figure 7 9 Page 7 11 3 Connect the black transformer primary coil wire 5 to the charger relay Figure 7 22 Page 7 25 4 Place a piece of heatshrink tubing over the AC cord wh...

Page 199: ... the white wires 2 and 3 from the ammeter 4 Figure 7 24 Page 7 31 4 Press the locking tabs on each side of the ammeter and remove the ammeter by gently pushing the ammeter through the front of the charger case Ammeter Installation 1 Place the ammeter 4 in position in the charger face and ensure that the locking tabs are secure Figure 7 24 Page 7 31 2 Connect the DC cord red wire 1 and the white wi...

Page 200: ...rom the rear of the charger 4 Install the charger cover RELAY BOARD ASSEMBLY See General Warning Section 1 Page 1 1 See additional WARNING on page 7 1 Relay Board Assembly Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect all wires from the relay Figure 7 9 Page 7 11 4 Remove two screws attaching relay to the front of ...

Page 201: ... charger AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face 2 Connect the AC cord black wire 1 to the AC circuit breaker 3 Figure 7 22 Page 7 25 3 Place a piece of heatshrink tubing 7 over the AC cord white wire 4 4 Connect the AC cord white wire 4 to the tan primary coil wire Figure 7 22 Page 7 25 5 Slide the heat...

Page 202: ...om the AC circuit breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 7 25 Page 7 35 See following DANGER 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 5 Plug the DC cord into the charger receptacle first and then plug the AC cord...

Page 203: ...above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual Figure 7 25 PowerDrive 3 Charger Wiring Diagram Relay Bypassed DC CORD RED BLUE BROWN BLACK AC CIRCUIT BREAKER AC CORD GREEN CASE GROUND ...

Page 204: ...7 ...

Page 205: ...tact your local Club Car dealer or distributor The IQ Plus battery charger is automatic and has no external controls Figure 8 1 Page 8 1 When the charger is connected there is a 2 to 15 second delay before charging begins See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging ...

Page 206: ...when the vehicle is being charged indicates a charg ing problem The battery warning light is controlled by the onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The batter...

Page 207: ...sitive 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 vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle ...

Page 208: ...ire or an electrical shock An extension cord or electrical outlet must accept a three prong plug Extension cord should be a three wire no 12 AWG American Wire Gauge and be as short as possible The use of improper extension cord could result in fire or an electrical shock Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not...

Page 209: ...r and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions With charger DC output cord disconnected connect the power supply cord to an AC supply See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment groun...

Page 210: ... following WARNING ý WARNING Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 8 3 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial cha...

Page 211: ...rger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death ý CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer a...

Page 212: ...y 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 NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the batteries are close to being fully charged the charge cycle will begin a...

Page 213: ...icing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Use the following Troubleshooting Guide for troubleshooting IQ Plus external battery chargers model num bers 25730 11 25730 18 and 25730 19 The Troubleshooting Guide encompasses the entire battery charg ing circuit Test procedures specified in the Troubleshooting Guide can...

Page 214: ...n audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Internal AC breaker Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Transformer primary coil Test Procedure 6 Tra...

Page 215: ...r trips AC cord is shorted Test Procedure 8 Continuity on page 8 20 Failed transformer Test Procedure 6 Transformer on page 8 18 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at four second intervals with DC charger cord plugged in AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 Onboard computer...

Page 216: ...ter 3 AC Power and Continuity Test of AC Circuit 4 Diodes 5 Charger DC Circuit Continuity Test 6 Transformer 7 Battery State of Charge Test 8 Continuity Figure 8 6 IQ Plus Battery Charger GREEN GROUND WIRE TAN WIRE TO PRIMARY COIL BLACK WIRE TO CIRCUIT BREAKER RED WIRE TO HEATSINK BLUE WIRE TO DC CORD TAN WIRE TO PRIMARY COIL BLACK WIRE TO RELAY RED WIRE OF DC CORD RED WIRE TO RELAY SECONDARY COIL...

Page 217: ...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 8 7 Page 8 13 3 5 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 fo...

Page 218: ...ICLES 1 3 5 7 8 2 4 6 1 3 5 7 8 2 4 6 Place multimeter black probe here Place multimeter black probe here Place multimeter red probe here Place multimeter red probe here Place multimeter red probe here Place multimeter black probe here TURF 2 252 VEHICLES CARRYALL 2 252 VEHICLES XRT 900 VEHICLES CARRYALL 6 VEHICLES STYLE B TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES STYLE A FRONT OF VEHICLE F...

Page 219: ...roperly If the charger per forms as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breaker on the front of the charger and reset it if necessary 3 Check the...

Page 220: ...ut being low open circuit diode If a diode has failed the entire heatsink must be replaced To check diodes 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect one transformer secondary coil wire from the diode terminal Figure 8 10 Page 8 17 4 Using a low voltage continuity tester or multimeter set to the diode test function conn...

Page 221: ...rger and the batteries both fuse links will blow when the DC cord is connected to the vehicle whether or not the AC cord is plugged into an outlet 3 On rare occasions both diodes may fail as a result of a lightning strike at the charging location 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 th...

Page 222: ...ircuit test should be done before performing this test procedure to ensure the continuity of the AC cord internal AC circuit breaker and charger wiring See Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 8 15 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect transformer secondary coil wires 1 and 5 from the...

Page 223: ...eshooting and repairs are complete properly connect relay wiring See following WARN ING ý 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 TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additi...

Page 224: ...s place the red probe on the terminal at the end of the black wire 1 Test for continuity on each of the flat blades and then on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord and plug must be replaced 7 Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat...

Page 225: ...unmarked middle pin of the DC plug The tester should indicate no continuity If tester registers continuity the DC cord must be replaced 13 Move continuity test probe to the blue wire of the DC cord Check for continuity at the middle pin The tester should indicate continuity If tester does not indicate continuity replace DC cord Transformer The IQ Plus battery charger transformer has two sets of co...

Page 226: ...ct terminals 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 4 Place continuity test probes on contact terminals of relay With batteries connected insert DC plug into receptacle The tester should indicate continuity If tester does not indicate continuity relay must be replaced Ammeter 1 Discon...

Page 227: ...le receptacle 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 8 17 Page 8 23 4 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink 5 Remove the wire tie that secures the DC cord wire to the secondary coil wire tan 6 Remove the wire tie...

Page 228: ...e to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 7 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in lb 1 2 N m HEATSINK See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 Heatsink Removal 1 Disconnect AC cord from the wall outlet and...

Page 229: ...nt the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in lb 3 2 N m Figure 8 6 Page 8 12 2 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in lb 2 5 N m 3 Connect the other secondary coil transformer wire bl...

Page 230: ...e the ammeter in position in the charger face Figure 8 18 Page 8 26 2 Install nuts 2 and tighten until ammeter is firmly secured 3 Connect the black wire of the DC cord 5 to the left as viewed from inside the charger post of the amme ter 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 5 Thread nuts 4 onto both posts of a...

Page 231: ... 5 N m 4 Install the charger cover VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 The voltage suppressor which is incorporated into a wire assembly in the charger protects the onboard com puter by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnect...

Page 232: ...a pair of pliers squeeze in the retaining tabs on the sides of the AC circuit breaker and remove the circuit breaker through the mounting hole in the face of the charger AC Circuit Breaker Installation 1 Install in reverse order of removal CHARGER AC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 8 1 AC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug ...

Page 233: ... the vehicle charger receptacle 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 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 ...

Page 234: ...G ý 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 9 Install the charger cover and the retaining screws 10 Plug the DC cord into the charger receptacle and plug the AC cord into an electrical outlet 11 Allow the charger to continue ...

Page 235: ... in vehicles other than IQ Plus vehi cles contact your local Club Car dealer or distributor The IQ Plus battery charger is automatic and has no external controls Figure 9 1 Page 9 1 When the charger is connected there is a 2 to 15 second delay before charging begins See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnosti...

Page 236: ...will indicate as follows The battery warning light will not illuminate if the charge is 90 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger AC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 sec...

Page 237: ... of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion ý WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer ...

Page 238: ...rom overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes 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 ONBOARD CHARGER AC POWER CONNECTION The AC...

Page 239: ...m 20 to 50 times 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 use the CDM Communication Display M...

Page 240: ...ay of 2 to 15 seconds 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 9 2 2 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that th...

Page 241: ...e 9 2 Page 9 3 Figure 9 3 Page 9 6 and Figure 9 4 Page 9 10 DC circuit Test Procedure 5 Charger DC Circuit Continuity Test on page 9 14 Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Gray sense lead fuse is blown Test Procedure 1 Battery Voltage on page 9 9 Control board malfunction Test Procedure 2 Control Board on page 9 11 Relay closes with an audible click but no tran...

Page 242: ...ge 9 11 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 9 17 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Control Board on page 9 11 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circui...

Page 243: ... the solenoid battery side for Carryall 6 Villager and TransPorter vehicles 1 2 Verify the connection of the 10 gauge black wire from the onboard computer to the 10 gauge black wire from the battery charger 1 3 Check the connection of the 18 gauge gray wire from the charger to the onboard computer gray wire 1 4 Turf 2 252 Carryall 2 252 and XRT 900 Only Check the fuse in the 18 gauge gray wire 2 W...

Page 244: ...3 5 7 8 2 4 6 1 3 5 7 8 2 4 6 Place multimeter black probe here Place multimeter black probe here Place multimeter red probe here Place multimeter red probe here Place multimeter red probe here Place multimeter black probe here TURF 2 AND 252 VEHICLES CARRYALL 2 AND 252 VEHICLES XRT 900 VEHICLES CARRYALL 6 VEHICLES STYLE B TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES STYLE A FRONT OF VEHICLE F...

Page 245: ...res remain connected to vehicle Set multimeter to volts AC 2 Disconnect tan wire from transformer primary coil at terminal on control board Figure 9 7 Page 9 12 See following DANGER 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 3 Place black probe of multimeter set to 200 volts AC onto term...

Page 246: ...it breaker and disconnect the black wire 4 from the relay Connect the black wire 4 to the AC circuit breaker Figure 9 11 Page 9 16 5 4 With relay bypassed there should be continuity across the AC cord blades Figure 9 8 Page 9 13 6 If the circuit is not complete check the wiring of the AC cord AC cord reel transformer primary coil wires and internal AC circuit breaker Figure 9 11 Page 9 16 7 If the...

Page 247: ...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 9 9 Page 9 14 6 Reverse test probes and check each diode again and note the reading Figure 9 10 Page 9 14 A diode is designed to conduct current in one direction only If a diode conducts current shows continuity in both ...

Page 248: ...e DC cord is connected to the vehicle whether or not the AC cord is plugged into an outlet 3 Make sure the charger is wired to the vehicle correctly the vehicle s DC cord red wire should be con nected to the same large solenoid post as the 6 gauge red wire connected to the positive post of bat tery no 1 The DC cord blue wire should be connected to the sense lead fuse The DC cord black wire should ...

Page 249: ... no continuity TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns If the transformer has failed the ammeter will indicate low output or no output however the transformer may hum A blown AC line fuse or tripped AC circuit breaker in the charger or the storage facility may be caused by an imp...

Page 250: ...y 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced Figure 9 11 Page 9 16 11 If the voltage reading is normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuity of the DC circuit See Test Procedure 5 Charger DC Circuit Continuity Test on page 9 14 12 When troubleshooting ...

Page 251: ...lack wire 1 of the short AC cord from charger AC circuit breaker 6 Disconnect the AC cord white wire 4 from the control board 7 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Figure 9 12 Page 9 18 Test for continuity on each of the flat blades and then on the round pin of the AC plug on the retractable cord reel The tester should indicate con...

Page 252: ... AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 9 13 Page 9 18 4 Disconnect the short AC cord from the retractable cord reel 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 9 14 Page 9 19 Figure 9 12 AC Cord and Retractable ...

Page 253: ... reading is obtained the AC cord and retract able cord reel must be tested independently of each other 11 If the correct readings are obtained in all of the previous steps the short AC cord is functioning properly Proceed to the following test procedure to test the retractable cord reel Retractable Cord Reel Check continuity of the AC cord and retractable cord reel at the same time 1 Disconnect th...

Page 254: ...move the charger cover 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 9 16 Page 9 22 4 Disconnect the red wire of the DC cord from the heatsink 5 Disconnect the blue wire from the control board 6 Using a multimeter set for 200 ohms place the red probe on the red wire of the DC cord Test for con tinuity on each of the wires on the other end...

Page 255: ...th of the 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 Relay 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 2 Remove the charger cover 3 Remove black wires from contact terminals of the relay Figure 9 11 Page 9 16 Place cont...

Page 256: ... Support the terminal as the nut is loosened to prevent rotation of the connection Figure 9 17 Page 9 22 4 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink 5 Remove the wire tie that secures the DC cord wire to the secondary coil wire tan 6 Remove the wire tie on the DC cord near the strain relief bushing 7 Disconnect the DC cord blue wire from the control board Figure 9 ...

Page 257: ...o 11 in lb 1 2 N m HEATSINK Heatsink Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See preceding WARNING 2 Remove the charger cover 3 Remove both secondary coil transformer wires tan from the heatsink Figure 9 3 Page 9 6 4 Remove the two red wires from the heatsink 5 Remove the nuts and bolts that secure the heatsink to th...

Page 258: ...oil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in lb 2 0 N m 3 Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in lb 2 0 N m 4 Connect one secondary coil transformer wire black to one terminal of the fuse assembly Tighten nut to 22 in lb 2 5 N m 5 Connect the other secondary coil transformer wi...

Page 259: ...ly secured 3 Connect the black wire 5 of the DC cord to the left as viewed from inside the charger post of the amme ter 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 5 Thread nuts 4 onto both posts of ammeter until just past finger tight While holding the inside nut tighten the outside nut 4 1 4 turn See following CAUT...

Page 260: ...er when viewed from the front of the charger 2 Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 9 18 Page 9 25 Tighten to 22 in lb 2 5 N m 3 Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tighten...

Page 261: ... two black wires attached to the AC circuit breaker Figure 9 19 Page 9 27 4 Remove the nut on the front face of the charger that secures the breaker and remove the breaker from the charger AC Circuit Breaker Installation 1 Install in reverse order of removal Tighten nut firmly CHARGER AC CORD AND RETRACTABLE CORD REEL See General Warning Section 1 Page 1 1 Short AC Cord Removal 1 Disconnect the AC...

Page 262: ... 9 31 See WARNING on page 9 22 2 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 9 13 Page 9 18 3 Disconnect the short AC cord from the retractable cord reel 4 Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transporter 4 and 6 Remove four screws 1 securing the cord reel housing 2 and its back...

Page 263: ... in the NEUTRAL position 2 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 9 31 See WARNING on page 9 22 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 rela...

Page 264: ...ly 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 10 Install charger cover and install charger in vehicle See Onboard Charger Installation on page 9 31 11 Plug the AC cord into an electrical outlet 12 Allow the charger to continue charging the batteries until the charger sh...

Page 265: ... reel Figure 9 13 Page 9 18 4 Remove hardware securing charger to chassis 4 1 Villager 6 and 8 Remove four bolts 2 flat washers 3 lock washers 4 and nuts 5 from charger mounting plates 4 2 Carryall 2 252 Turf 2 252 and XRT 900 Remove two bolts 2 from topside of charger mounting plate 4 3 Carryall 6 and Transporter 4 and 6 Remove two nuts 5 from underside of charger mounting plate 5 Lift charger as...

Page 266: ... 2008 2011 Domestic Battery Charger Maintenance and Service Manual 9 Figure 9 22 Onboard Charger Mounting Details TURF 2 AND 252 CARRYALL 2 AND 252 XRT 900 TRANSPORTER 4 TRANSPORTER 6 CARRYALL 6 To AC Cord Reel Route behind batteries VILLAGER 6 VILLAGER 8 5 6 5 4 3 1 1 1 2 2 ...

Page 267: ...ry Charger functions as an integral part of the vehicles electrical system and will not work with other electric vehicles The charger is programmed with a specific charge algorithm that is appropriate to the specific battery type used in the vehicle See Battery Charger Identification on page 2 1 When the charger AC cord is connected LED lights on the charger and dash perform start up self test LED...

Page 268: ...automatically activate if battery voltage drops 2 1 Volts per cell 24 cells is 50 4 Volts or 30 days have elapsed To return the vehicle to service disconnect the AC cord from the wall outlet wait 15 seconds and then plug the AC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before put ting it into service UL AND CSA LISTING When operated on a 120 volt 60...

Page 269: ...gauge red wire from the positive post of battery no 1 3 Plug the AC power supply cord into the wall outlet See following NOTE NOTE When the charger AC cord is connected LED lights on the charger and dash perform start up self test LEDs light up in sequence 4 After the start up self test the 80 LED will display a series of flashes that represent the algorithm num ber Figure 10 2 Page 10 3 Example A...

Page 270: ...unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion Risk of electric shock Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances A grounded outlet is required to reduce risk of electric shock do not use ground adapters or modify plug Do not touch unin...

Page 271: ...ly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock Use only an appropriately sized AC power cord See AC Power Connection on page 10 7 Do not use near fuels grain dust sol...

Page 272: ...o battery connected indicates algorithm selected by number of flashes 100 Charge Green Solid Charging complete Charger in Maintenance Mode Flashing Absorption phase complete In Finish phase AC On Amber Solid AC Power good Flashing Low AC Voltage Check voltage and power cord length see above for guidelines Fault Red Flashing Charger error Reset charger power and refer to Troubleshooting Instruction...

Page 273: ...r is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak contact a local Club Car distribu tor dealer New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf b...

Page 274: ... is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic ser vice ý WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repa...

Page 275: ...eter on page 10 10 If not replace with correct battery set Reset charger interrupt AC power for 15 seconds Battery Low Voltage Ensure battery set is rated 48 volts and composed of 24 cells Also check the voltage of each individual battery See Test Procedure 1 Battery Voltage Using Multimeter on page 10 10 If not replace with correct battery set Reset charger interrupt AC power for 15 seconds Charg...

Page 276: ...r AC plug The red LED in the Charger Information Light will flash quickly and then flash slowly within 10 to 20 minutes indicating sound fully charged batteries NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper and the red Charger Information Light will continue to flash quickly See Batteries Section in the appro priate maintenance and service manu...

Page 277: ...DROMETER TEST FLOODED LEAD ACID BATTERIES ONLY A hydrometer measures the specific gravity of the battery s electrolyte The higher the specific gravity the higher the state of charge of the batteries A fully charged battery should read between 1 250 and 1 280 at 80 F 26 7 C Never add acid to batteries to obtain a higher specific gravity Performing the Hydrometer Test 1 Be sure batteries have suffic...

Page 278: ...00 1 220 1 240 75 1 190 1 210 50 1 160 1 180 25 VEHICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CORRECTED SPECIFIC GRAVITY REQUIRED ACTION CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 12 1 20 F 6 6 C 0 024 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 Sound Battery Fully Charged 54 3 50 F 10 C 0 012 1 260 0 012 1 248 1 200 ...

Page 279: ...ICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CORRECTED SPECIFIC GRAVITY REQUIRED ACTION CELL 1 CELL 2 CELL 3 CELL 4 12 1 20 F 6 6 C 0 024 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 1 280 0 024 1 256 Sound Battery Fully Charged 35 6 90 F 32 2 C 0 004 1 155 0 004 1 159 1 165 0 004 1 169 1 160 0 004 1 164 1 165 0 004 1 169 Discharged Battery Recharge 54 3 50 F 10 C 0 012 1 ...

Page 280: ...t in all cells 2 Connect the tester leads to the positive post of battery no 1 and negative post of battery no 4 last Style A and B 4 x 12 Volt Precedent Figure 10 5 Page 10 15 and Figure 10 6 Page 10 15 or no 6 last Style C 6 x 8 Volt Precedent Figure 10 7 Page 10 15 3 Check and record the electrolyte temperature of the battery packs Check cell no 2 second cell from positive post in each battery ...

Page 281: ... 42 0 volts use a multim eter to measure individual battery voltages Measure and record the voltage of each battery to the near est 0 01 volt See following NOTE NOTE The tester will shut off automatically when shut off voltage is reached Figure 10 5 Battery Discharge Test Precedent Style A Battery Configuration Figure 10 6 Battery Discharge Test Precedent Style B Battery Configuration Figure 10 7 ...

Page 282: ...ischarge times at various temperatures of a set of bat teries that delivers 62 minutes at 80 F 26 7 C BATTERY VOLTAGES BATTERY CONDITION 1 2 3 4 10 50 V 10 50 V 10 50 V 10 50 V Excellent 10 60 V 10 60 V 10 83 V 9 75 V Battery no 4 is near end of useful life 10 8 V 10 8 V 10 01 V 9 41 V Battery nos 3 and 4 are near end of useful life ELECTROLYTE TEMPERATURE DISCHARGE TIME TO SHUT OFF POINT ELECTROL...

Page 283: ...rious temperatures of a set of bat teries that delivers 62 minutes at 80 F 26 7 C BATTERY VOLTAGES BATTERY CONDITION 1 2 3 4 5 6 7 00 V 7 00 V 7 00 V 7 00 V 7 00 V 7 00 V Excellent 7 07 V 7 07 V 7 22 V 6 50 V 7 07 V 7 07 V Battery no 4 is near end of useful life 7 20 V 7 20 V 6 67 V 7 33 V 6 27 V 7 33 V Battery nos 3 and 5 are near end of useful life ELECTROLYTE TEMPERATURE DISCHARGE TIME TO SHUT ...

Page 284: ... set of bat teries that delivers 62 minutes at 80 F 26 7 C BATTERY VOLTAGES BATTERY CONDITION 1 2 3 4 5 6 7 8 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V Excellent 5 30 V 5 30 V 5 45 V 4 70 V 5 30 V 5 30 V 5 30 V 5 30 V Battery no 4 is near end of useful life 5 40 V 5 40 V 5 00 V 5 40 V 4 60 V 5 40 V 5 40 V 5 40 V Battery nos 3 and 5 are near end of useful life ELECTROLYTE TEMPERATURE ...

Page 285: ...ould be watched a little more closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system c...

Page 286: ...e watched a little more closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger...

Page 287: ...ore closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on ch...

Page 288: ...igure 10 3 Page 10 4 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle Onboard Charger Removal 1 Disconnect the batteries and discharge the controller See Disconnecting The Batteries on page 1 3 2 Remove the wire ties securing the AC cord to the body 3 Disconnect the charger AC cord from the charger harness 4 Dis...

Page 289: ...harge circuit 10 4 general information 10 1 test procedures 1 battery voltage 10 10 2 battery condition using charger 10 10 3 on charge battery voltage 10 10 4 hydrometer test 10 11 5 discharge test 10 14 troubleshooting 10 9 12 volt battery troubleshooting examples 10 19 6 volt battery troubleshooting examples 10 21 8 volt battery troubleshooting examples 10 20 IQ Plus charger external AC circuit...

Page 290: ...low voltage 9 29 state of charge test 9 17 battery charger installation 9 31 removal 9 31 repairs 9 22 testing 9 6 battery condition after a charge cycle 9 5 battery warning light 9 2 charge circuit 9 2 circuit breaker installation 9 27 removal 9 27 testing 9 21 control board testing 9 11 cord charger see AC cord or DC cord DC cord installation 9 22 removal 9 22 testing 9 14 9 20 diodes charger se...

Page 291: ...ation 5 27 removal 5 27 long term storage charge 5 2 onboard computer testing 5 15 rectifier installation 5 25 removal 5 24 testing 5 16 relay installation 5 28 removal 5 28 testing 5 22 suppressor voltage see voltage suppressor test procedures 1 faulty receptacle connection 5 13 1 low battery voltage 5 13 2 onboard computer 5 15 3 AC cord continuity check 5 15 3 AC power 5 15 4 rectifier 5 16 5 D...

Page 292: ...5 DC circuit continuity test 6 21 6 transformer 6 22 7 battery state of charge 6 23 8 continuity AC circuit breaker internal 6 26 AC cord and plug 6 23 ammeter 6 26 DC cord 6 25 relay 6 26 transformer 6 25 voltage suppressor 6 26 transformer installation 6 29 removal 6 29 testing 6 22 6 25 troubleshooting 6 12 voltage suppressor testing 6 26 PowerDrive 3 charger Model 26580 AC circuit breaker char...

Page 293: ... 30 removal 7 30 testing 7 23 7 26 troubleshooting 7 12 voltage suppressor testing 7 26 PowerDrive charger external AC circuit breaker charger see circuit breaker AC cord installation 3 33 removal 3 32 testing 3 24 ammeter installation 3 30 removal 3 30 testing 3 26 batteries battery condition after a charge cycle 3 12 charging batteries that have low voltage 3 34 state of charge test 3 23 battery...

Page 294: ...er a charge cycle 4 6 charging batteries that have low voltage 4 31 state of charge test 4 18 battery charger charger features 4 2 identification 2 1 installation 4 34 4 35 operation 4 5 removal 4 33 4 34 repairs 4 24 specifications 2 2 testing 4 6 battery warning light 4 2 charge circuit 4 2 charge interlock 4 2 circuit breaker installation 4 29 removal 4 29 testing 4 23 control board testing 4 1...

Page 295: ... circuit breaker internal 4 23 AC cord with retractable cord reel 4 19 AC cord without retractable cord reel 4 19 ammeter 4 23 DC cord 4 22 relay 4 23 retractable cord reel 4 21 transformer 4 23 transformer installation 4 26 removal 4 26 testing 4 17 troubleshooting 4 7 W WARNING definition of 1 1 ...

Page 296: ...Club Car R NOTES ...

Page 297: ... Information 3 Clarity of Illustrations Photos 4 Index Usability In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 5 If you are reviewing a Kit Instruction were all indicated parts included in your kit Yes No I am Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent O...

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Page 300: ...Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 ...

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