EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
Charger Installation and Operation
Page 3-12
2008 Export Battery Charger Maintenance and Service Manual
3
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WARNING
• Do not rock or bend the DC plug. To connect the charger plug to the vehicle receptacle, grasp
the plug handle and push the plug straight into the receptacle (Figure 3-8, Page 3-10).
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 that are higher or lower than the nominal input
voltage. Higher AC line 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 NOTE.
NOTE:
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 batteries require more time to fully charge.
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 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. Charging between rounds will also
extend battery life; use the CDM (Communication Display Module) (CCI P/N 101831801).
See
Communication Display Module (CDM) in Section 11 of the appropriate maintenance and
service manual.
TESTING CHARGER OPERATION
1. With the DC plug disconnected from the vehicle charger receptacle, insert the AC cord into an outlet. The
charger relay should NOT close. A multimeter set to volts DC and connected across the DC plug positive
(+) and negative (–) pins should indicate zero volts. No transformer hum should be heard.
2. Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle. The charger relay
should close with an audible click after a 2 to 15 second delay.
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 3-2.
3. If the charger does not operate exactly as described above, refer to the wiring diagram and make sure
that the vehicle is wired correctly
(Figure 3-2, Page 3-3 through Figure 3-7, Page 3-8)
and that the
internal charger wiring is correct
(Figure 3-11, Page 3-13)
.
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