Club Car Carryall 300 2021, Maintenance And Service Manual

Page: 260 / 596

15
Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER
EXTERNAL CHARGER TROUBLESHOOTING GUIDE
1. Erroneous event
(an unknown variable;
something occurred to
the charger or vehicle that
was not the fault of either)
Reset charger power. See Resetting Power – External
Charger on page 15-24. Reconnect DC cord to vehicle.
If status goes away, continue using charger.
2. Battery high voltage
Ensure battery set is rated 48 volts and composed
of 24 cells. See Battery Voltage Using Multimeter
on page 15-29. If not, replace with correct battery
set. Reset charger power. See Resetting Power
– External Charger on page 15-24.
3. Battery low voltage
Ensure battery set is rated 48 volts and composed of 24
cells. Also, check the voltage of each individual battery.
See Battery Voltage Using Multimeter on page 15-29. If
not, replace with correct battery set. Reset charger power.
See Resetting Power – External Charger on page 15-24.
4. Charge timeout caused
by battery pack not
reaching required voltage.
Check for loose or corroded connections. Check for old or
defective batteries. See Test Procedures on page 15-29.
5. Bad battery pack
Test battery pack health. Look for shorted or
damaged cells. See Battery Condition Using
Charger on page 15-30. See also Electric Vehicle
- Batteries on page 14-1.
6. AC voltage
out-of-range
Test and inspect incoming AC power. See AC Power and
Continuity Test of AC Circuit on page 15-30.
7. Ambient temperature
too hot (above 104
°F (40 °C))
Check for dirty, obstructed, or damaged cooling fins.
Clean if necessary and ensure sufficient cooling air
flow. Chargers stacked on top of or located too close
to each other. Move chargers farther apart. If issue
continues, wait for ambient temperature to cool or
relocate charger to a cooler environment.
8. Ambient temperature
too cold (below -40
°F (-40 °C))
Wait for ambient temperature to warm or relocate
charger to a warmer environment.
9. Bad DC connection
Inspect charger receptacle, receptacle harness
connections and DC cord connection to charger. See DC
Plug and Receptacle on page 15-29. See Charger
DC Circuit Continuity Test on page 15-31.
Flashing
orange
Charger unable to
complete charge.
(Usually not
related to charger
itself. Something
occurred to prevent
the charger from
completing the
charge. Check
external factors
first.)
10. Corroded or loose
connections
Clean or tighten connections.
1. Charger abnormality
Reset charger power. See Resetting Power – External
Charger on page 15-24. Reconnect DC cord to vehicle.
If status goes away, proceed to charge again. See
Charger Output Test on page 15-31.
If status occurs again during the next charge cycle,
attempt to charge with another identical charger. If
charge is successful, proceed to step 2. If status
occurs again, troubleshoot the AC power supply,
vehicle and battery pack.
Solid red Charger error
2. Charger internal fault Replace charger.
Page 15-26 2021 Carryall 300 Maintenance and Service Manual