Club Car 2005 Domestic Manual

BATTERY CHARGERS
DOMESTIC
&
2005MAINTENANCE & SERVICE MANUAL
Manual No. 102680414 Edition Code 1204A00000
®

2005 Domestic Battery Charger Maintenance and Service Manual Page i
FOREWORD
Club Car battery chargers are designed and built to provide unsurpassed performance efficiency among
chargers in their class; however, proper maintenance and repair are essential for achieving maximum service
life and continued safe and reliable operation.
This manual provides detailed information for the maintenance and repair of domestic Club Car battery charg-
ers, and should be thoroughly reviewed prior to servicing the charger. The procedures provided herein must
be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
This manual was written for the trained technician who already has knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to
the vehicle or charger may render the vehicle or charger unsafe. For this reason, Club Car advises that all
repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club
Car factory-trained technician.
It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
This manual covers all aspects of typical battery charger service; unique situations, however, do sometimes
occur when servicing a charger. If it appears that a service question is not answered in this manual, you may
write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917; Attention: Technical Services, or
contact a Club Car Technical Service Representative at [phone], ext. 3580.
Copyright © 2004 Club Car, Inc.
Club Car and PowerDrive are registered
trademarks of Club Car, Inc.
This manual effective August 2, 2004.

Page ii 2005 Domestic Battery Charger Maintenance and Service Manual
ý WARNING
• Read Section 1 – Safety before attempting any service on a Club Car vehicle or charger.
• Before servicing a Club Car vehicle or charger, read complete section(s) and any referenced
information that may be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is
continually working to further 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, Inc. reserves the right to change specifications and designs at any time without notice
and without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658,
USA, Attention: Warranty Administration.

2005 Domestic Battery Charger Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
SECTION 2 – CHARGER IDENTIFICATION AND SPECIFICATIONS
General Information .......................................................................................................................... 2-1
Specifications .................................................................................................................................... 2-1
Battery Charger Identification ........................................................................................................... 2-4
SECTION 3 – POWERDRIVE CHARGER (EXTERNAL)
General Information .......................................................................................................................... 3-1
PowerDrive External Charger Features ........................................................................................ 3-2
Battery Warning Light ................................................................................................................... 3-2
The Charge Circuit ............................................................................................................................ 3-3
Charger Installation and Operation ................................................................................................... 3-5
AC Power Connection .................................................................................................................. 3-6
Charging Batteries ........................................................................................................................ 3-6
Testing Charger Operation ........................................................................................................... 3-8
DC Cord and Plug Inspection ....................................................................................................... 3-8
Checking Battery Condition After a Charge Cycle ............................................................................ 3-9
Start Charge Cycle ....................................................................................................................... 3-9
Troubleshooting ................................................................................................................................ 3-9
Test Procedures ............................................................................................................................... 3-12
Index of Test Procedures .............................................................................................................. 3-12
Charger Repairs ............................................................................................................................... 3-23
DC Cord ........................................................................................................................................ 3-23
Heatsink ........................................................................................................................................ 3-24
Transformer .................................................................................................................................. 3-25
Ammeter ....................................................................................................................................... 3-26
Fuse Link ...................................................................................................................................... 3-27
Voltage Suppressor ...................................................................................................................... 3-27
Charger Relay ............................................................................................................................... 3-28
Charger AC Circuit Breaker .......................................................................................................... 3-28
Charger AC Cord .......................................................................................................................... 3-28
Charging a Battery Pack that has Low Voltage ................................................................................ 3-29

Page iv 2005 Domestic Battery Charger Maintenance and Service Manual
SECTION 4 – CARRYALL 6 AND TRANSPORTER POWERDRIVE CHARGER (ON-
BOARD)
General Information ......................................................................................................................... 4-1
PowerDrive Onboard Charger Features ....................................................................................... 4-2
Battery Warning Light ................................................................................................................... 4-2
The Charge Circuit ........................................................................................................................... 4-2
Charger Operation ........................................................................................................................... 4-3
Checking Battery Condition .............................................................................................................. 4-6
Troubleshooting ............................................................................................................................... 4-6
Test Procedures ............................................................................................................................... 4-9
Index of Test Procedures ............................................................................................................. 4-9
Charger Repairs ............................................................................................................................... 4-21
DC Cord ....................................................................................................................................... 4-22
Heatsink ....................................................................................................................................... 4-23
Transformer .................................................................................................................................. 4-23
Ammeter ....................................................................................................................................... 4-24
Fuse Link ...................................................................................................................................... 4-25
Charger Relay .............................................................................................................................. 4-26
Charger AC Circuit Breaker .......................................................................................................... 4-27
Charger AC Cord and Retractable Cord Reel .............................................................................. 4-27
Retractable AC Cord Reel ............................................................................................................ 4-28
Charging a Battery Pack that has Low Voltage ................................................................................ 4-28
Onboard Charger Removal and Installation ..................................................................................... 4-30
SECTION 5 – POWERDRIVE 2 CHARGER (EXTERNAL)
General Information ......................................................................................................................... 5-1
PowerDrive 2 Battery Charger Features ...................................................................................... 5-2
Battery Warning Light ................................................................................................................... 5-2
The Charge Circuit ........................................................................................................................... 5-3
Charger Installation and Operation .................................................................................................. 5-4
AC Power Connection .................................................................................................................. 5-6
Charging Batteries ........................................................................................................................ 5-6
Testing Charger Operation ........................................................................................................... 5-7
DC Cord and Plug Inspection ....................................................................................................... 5-8
Checking Battery Condition After a charge Cycle ............................................................................ 5-9
Start Charge Cycle ....................................................................................................................... 5-9
Troubleshooting ............................................................................................................................... 5-9
Test Procedures ............................................................................................................................... 5-12
Index of Test Procedures ............................................................................................................. 5-12

2005 Domestic Battery Charger Maintenance and Service Manual Page v
Charger Repairs ............................................................................................................................... 5-23
DC Cord ........................................................................................................................................ 5-24
Rectifier ......................................................................................................................................... 5-25
Transformer .................................................................................................................................. 5-26
Ammeter ....................................................................................................................................... 5-27
Fuse Link ...................................................................................................................................... 5-28
Voltage Suppressor ...................................................................................................................... 5-28
Charger Relay ............................................................................................................................... 5-29
Charger AC Circuit Breaker .......................................................................................................... 5-29
Charger AC Cord .......................................................................................................................... 5-29
Charging a Battery Pack that has Low Voltage ................................................................................ 5-30
SECTION 6 – GE POWERDRIVE CHARGER (EXTERNAL)
General Information .......................................................................................................................... 6-1
GE PowerDrive Battery Charger Features ................................................................................... 6-2
Battery Warning Light ................................................................................................................... 6-2
The Charge Circuit ............................................................................................................................ 6-3
Charger Installation and Operation ................................................................................................... 6-4
AC Power Connection .................................................................................................................. 6-6
Charging Batteries ........................................................................................................................ 6-6
Testing Charger Operation ........................................................................................................... 6-7
DC Cord and Plug Inspection ....................................................................................................... 6-8
Checking Battery Condition After a charge Cycle ............................................................................. 6-9
Start Charge Cycle ....................................................................................................................... 6-9
Troubleshooting ................................................................................................................................ 6-9
Test Procedures ............................................................................................................................... 6-12
Index of Test Procedures .............................................................................................................. 6-12
Charger Repairs ............................................................................................................................... 6-23
DC Cord ........................................................................................................................................ 6-24
Rectifier ......................................................................................................................................... 6-25
Transformer .................................................................................................................................. 6-26
Ammeter ....................................................................................................................................... 6-27
Fuse .............................................................................................................................................. 6-28
Voltage Suppressor ...................................................................................................................... 6-28
Charger Relay ............................................................................................................................... 6-29
Charger AC Circuit Breaker .......................................................................................................... 6-29
Charger AC Cord .......................................................................................................................... 6-29
Charging a Battery Pack that has Low Voltage ................................................................................ 6-30
SECTION i – INDEX

2005 Domestic Battery Charger Maintenance and Service Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing Club Car vehicles or battery chargers, and to protect the vehicles and
battery chargers from damage resulting from improper service or maintenance, the procedures in this manual
must be followed.
It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAU-
TION. These special statements relate to specific safety issues, and must be read, understood, and heeded
before proceeding with procedures. There are also statements labeled NOTE, which provide other essential
service or maintenance information.
ý DANGER
• A DANGER indicates an immediate hazard that will result in severe personal injury or death.
ý WARNING
• A WARNING indicates an immediate hazard that could result in severe personal injury or
death.
ý CAUTION
• A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that 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 general safety statements, which
can be found throughout this manual. Also, other specific warnings appear throughout this manual and on the
vehicle and battery charger.
ý DANGER
• Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full
face shield and rubber gloves when working on or near batteries.
• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
- Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
- Eyes: Flush with water for 15 minutes. Call a physician immediately.

SAFETY General Warning
Page 1-2 2005 Domestic Battery Charger Maintenance and Service Manual
1
ý WARNING
• Do not leave children unattended on vehicle.
• Only trained technicians should repair or service the vehicle or battery charger. Anyone doing
even simple repairs or service should have knowledge and experience in electrical and
mechanical repair.
• Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those on the vehicle and battery charger.
• Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
• Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
• Wear safety glasses or approved eye protection when servicing the vehicle or battery charger.
Wear a full face shield and rubber gloves when working on or near batteries.
• Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle or battery charger.
• Moving parts! Do not attempt to service the vehicle while it is running.
• Hot! Do not attempt to service hot motor or resistors. Failure to heed this warning could result
in severe burns.
• Use insulated tools when working near batteries or electrical connections. Use extreme
caution 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. Failure to heed
this warning could result in severe personal injury or death.
• Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle or switch in the NEUTRAL position.
Chock the wheels when servicing the vehicle.
• IQ System vehicles:
Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries.
Failure to heed this warning could result in a battery explosion or severe personal injury.
• All electric vehicles:
To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-1,
Page 1-3, Figure 1-2, Page 1-3, or Figure 1-3, Page 1-3).
• IQ System vehicles:
After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
• PowerDrive System 48 vehicles:
After disconnecting the batteries, discharge the controller capacitors as follows:
- Turn key switch to ON and place the Forward/Reverse handle or switch in REVERSE.
- Slowly press the accelerator pedal and keep it pressed until the reverse warning buzzer can
no longer be heard. When the buzzer stops sounding, the controller capacitors are
discharged.
• Never push objects of any kind into the battery charger case through the ventilation slots.
Failure to heed this warning could result in an electrical short circuit that could result in a fire.
• 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.
WARNING CONTINUED ON NEXT PAGE...

SAFETY General Warning
2005 Domestic Battery Charger Maintenance and Service Manual Page 1-3
1
ý WARNING
• External battery chargers:
Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and
the DC plug from the vehicle charger receptacle.
• Onboard battery chargers:
Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet and
remove the battery charger from the vehicle. See Onboard Charger Removal, Section 4,
Page 4-30.
• If wires are removed or replaced make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property 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 service
procedure that requires movement of the wheels, lock the brakes.
Figure 1-1 PowerDrive System 48 Battery Configuration
Figure 1-2 DS IQ System Battery Configuration Figure 1-3 Precedent IQ System Battery Configuration
1
2
3
4
6
5
1
2
3
4
6
5
DISCONNECT
BATTERY CABLES HERE
DISCONNECT
BATTERY CABLES HERE
Remove
negative
cable first.
Remove
negative
cable first.
FRONT
OF VEHICLE
Refer to the appropriate battery configuration.
TOW RUN
WARNING
1
2
3
4
6
5
FRONT
OF VEHICLE
Place Tow/Run
switch in TOW.
Remove negative
cable first.
PLACE TOW/RUN SWITCH
IN THE TOW POSITION BEFORE
DISCONNECTING OR
CONNECTING BATTERY CABLES
CCI102519501
RUN
TOW
Place Tow/Run
switch in TOW.
Remove negative (–)
cable first.
Place TOW/RUN Switch in the TOW
position before disconnecting or
connecting battery cables. 12
3
4
FRONT
OF VEHICLE
CCI 102519501
RUN
TOW

1

2005 Domestic Battery Charger Maintenance and Service Manual Page 2-1
2
SECTION 2 – CHARGER IDENTIFICATION AND
SPECIFICATIONS
GENERAL INFORMATION
There are several different Club Car battery charger models available. It is important to properly identify the
battery charger type and model number before attempting to service a Club Car battery charger. See Battery
Charger Identification on page 2-4.
SPECIFICATIONS
POWERDRIVE 48 VOLT
EXTERNAL CHARGER
SPECIFICATIONS
PowerDrive Battery Charger PowerDrive Battery Charger
Model number
(CCI P/N)
17930-11
(101802201)
17930-18
(101802202)
17930-19
(101802203)
IC3645B12A
4ASC1
(102496401)
IC3645B12A
4BSC1
(102496402)
IC3645B12A
4CSC1
(102496403)
AC input
AC voltage: 105-128 VAC (acceptable range) • • • • • •
Frequency: 60 Hz. • • • • • •
Power consumption
Max. AC current (amps) 10.71 10.71 10.71 9.0 9.0 9.0
DC output
DC voltage (VDC)
(start of charge cycle) 48 48 48 48 48 48
DC current (amps)
(start of charge cycle) 17 17 17 15 15 15
DC voltage (VDC)
(end of charge cycle) 60 60 60 60 60 60
DC current (amps)
(end of charge cycle) 3.53.53.53.53.53.5
Dimensions/Weight
Case – overall length 10.25 in.
(26 cm)
10.25 in.
(26 cm)
10.25 in.
(26 cm)
7.3 in.
(18.5 cm)
7.3 in.
(18.5 cm)
7.3 in.
(18.5 cm)
Case – overall width 8.687 in.
(22.1 cm)
8.687 in.
(22.1 cm)
8.687 in.
(22.1 cm)
8.0 in.
(20.3 cm)
8.0 in.
(20.3 cm)
8.0 in.
(20.3 cm)
Case – overall height 9.0 in.
(22.9 cm)
9.0 in.
(22.9 cm)
9.0 in.
(22.9 cm)
8.6 in.
(21.8 cm)
8.6 in.
(21.8 cm)
8.6 in.
(21.8 cm)
AC cord length 74 in.
(188 cm)
108 in.
(274.3 cm)
108 in.
(274.3 cm)
74 in.
(188 cm)
108 in.
(274.3 cm)
108 in.
(274.3 cm)
DC cord length 103 in.
(261.6 cm)
144 in.
(365.8 cm)
240 in.
(609.6 cm)
103 in.
(261.6 cm)
144 in.
(365.8 cm)
240 in.
(609.6 cm)
Weight 31 lb
(14.1 kg)
31.6 lb
(14.3 kg)
33 lb
(15.0 kg)
24 lb
(10.9 kg)
24.6 lb
(11.2 kg)
26 lb
(11.8 kg)
Mounting configuration
Mounting: Set on shelf, wall mount with keyhole,
or hang securely from ceiling. ••••••

CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications
Page 2-2 2005 Domestic Battery Charger Maintenance and Service Manual
2
POWERDRIVE 2 48 VOLT
EXTERNAL CHARGER
SPECIFICATIONS
PowerDrive 2 Battery Charger
Model number
(CCI P/N) 22110-11 (101802204) 22110-18 (101802205) 22110-19 (101802206)
AC input
AC voltage: 105-128 VAC (acceptable range) • • •
Frequency: 60 Hz. • • •
Power consumption
Max. AC current (amps) 9.0 9.0 9.0
DC output
DC voltage (VDC)
(start of charge cycle) 48 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 in.
(274.3 cm)
108 in.
(274.3 cm)
DC cord length 103 in.
(261.6 cm)
144 in.
(365.8 cm)
240 in.
(609.6 cm)
Weight 24 lb
(10.9 kg)
24.6 lb
(11.2 kg)
26 lb
(11.8 kg)
Mounting configuration
Mounting: Set on shelf, wall mount with keyhole, or hang securely
from ceiling. •••
48 VOLT POWERDRIVE ONBOARD
CHARGER SPECIFICATIONS PowerDrive Battery Charger (Onboard)
Model number
(CCI P/N)
17935-10
(101814301)
17935-20
(101814303)
17935-30
(101814304)
AC input
AC voltage: 105-128 VAC (acceptable range) • • •
Frequency: 60 Hz. • • •
Power consumption
Max. AC current (amps) 10.71 10.71 10.71
Specifications continued on next page...

CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications
2005 Domestic Battery Charger Maintenance and Service Manual Page 2-3
2
DC output
DC voltage (VDC) (start of 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 9.437 in.
(24 cm)
9.437 in.
(24 cm)
9.437 in.
(24 cm)
AC cord length 17 ft. (5.2 m)
(retractable)
17 ft. (5.2 m)
(retractable)
17 ft. (5.2 m)
(retractable)
DC cord length 80.5 in.
(204.5 cm)
129.5 in.
(328.9 cm)
162.5 in.
(412.8 cm)
Weight 37 lb (16.8 kg) 37.7 lb (17.1 kg) 38.2 lb (17.3 kg)
Mounting Configuration
Mounting: Onboard (secured to the vehicle) •••
48 VOLT POWERDRIVE ONBOARD
CHARGER SPECIFICATIONS PowerDrive Battery Charger (Onboard)
Model number
(CCI P/N)
17935-10
(101814301)
17935-20
(101814303)
17935-30
(101814304)

CHARGER IDENTIFICATION AND SPECIFICATIONS Battery Charger Identification
Page 2-4 2005 Domestic Battery Charger Maintenance and Service Manual
2
BATTERY CHARGER IDENTIFICATION
The battery charger can be identified by the model number printed on the charger. Refer to the appropriate
section of this manual, as indicated in the chart below, for information on troubleshooting and repairing the
battery charger. Do not attempt to service a battery charger that cannot be properly identified. If a charger
cannot be identified, contact your local Club Car dealer or distributor.
BATTERY CHARGER NAME
AND MODEL NUMBER REFER TO
PowerDrive Battery Charger
17930-11 (101802201)
Section 3 – PowerDrive
Charger (External)
PowerDrive Battery Charger
17930-18 (101802202)
PowerDrive Battery Charger
17930-19 (101802203)
PowerDrive Battery Charger (Onboard)
17935-10 (101814301)
Section 4 – Carryall 6 and
TransPorter PowerDrive
Charger (Onboard)
PowerDrive 2 Battery Charger
22110-11 (101802204)
Section 5 – PowerDrive 2
Charger (External)
PowerDrive 2 Battery Charger
22110-18 (101802205)
PowerDrive 2 Battery Charger
22110-19 (101802206)
PowerDrive Battery Charger
IC3645B12A4ASC1 (102496401)
Section 6 – GE PowerDrive
Charger (External)
PowerDrive Battery Charger
IC3645B12A4BSC1 (102496402)
PowerDrive Battery Charger
IC3645B12A4CSC1 (102496403)
PowerDrive Battery Charger (Onboard)
17935-20 (101814303) Optional equipment. Contact
your Club Car technical repre-
sentative or the Club Car Tech-
nical Hotline for service
concerns.
PowerDrive Battery Charger (Onboard)
17935-30 (101814304)

2005 Domestic Battery Charger Maintenance and Service Manual Page 3-1
3
SECTION 3 – POWERDRIVE CHARGER
(EXTERNAL)
ý DANGER
• See General Warning, Section 1, Page 1-1.
ý WARNING
• See General Warning, Section 1, Page 1-1.
• The battery charger DC plug must be pulled slowly from the receptacle (Figure 3-5, Page 3-6).
Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and
receptacle and could cause batteries to explode (Figure 3-6, Page 3-6).
GENERAL INFORMATION
This section includes information pertaining to service of the PowerDrive battery charger (model numbers
17930-11, 17930-18, and 17930-19). Do not attempt to service a battery charger that has not been properly
identified. If a charger cannot be properly identified, contact your local Club Car dealer or distributor.
The PowerDrive battery charger is automatic and has no external controls (Figure 3-1, Page 3-1). When the
charger is connected, there is a 2 to 15 second delay before charging begins.
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
(ammeter returns to previous rate of charge). This will be repeated at one hour and at two hours
into the charge cycle.
The onboard computer, having recorded the amount of energy consumed as the vehicle was used, directs the
charger to replace 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 3-1 PowerDrive Battery Charger
Club Car

POWERDRIVE CHARGER (EXTERNAL) General Information
Page 3-2 2005 Domestic Battery Charger Maintenance and Service Manual
3
POWERDRIVE EXTERNAL CHARGER FEATURES
•ChargeInterlock
PowerDrive battery charger DC plugs have three pins rather than two blades common on most stan-
dard charger plugs. Two of these pins are the positive and negative leads as on standard chargers; the
third pin is a sensing lead that is the communication link between the charger and the onboard com-
puter. When the charger plug is plugged into the vehicle receptacle, the onboard computer locks out
the vehicle drive system. This prevents the possibility of driving the vehicle while the charger is plugged
in and potentially damaging the vehicle and charger. See following WARNING.
• Long-Term Storage Charge
IQ System, PowerDrive, and Precedent vehicles with PowerDrive chargers are designed to be left con-
nected with AC power to the charger during off-season or long-term storage. The onboard computer
will automatically activate the charger every 15 days. To return the vehicle to service, unplug the
charger DC cord, wait 15 seconds for the computer to reset, and plug the charger back in. See follow-
ing WARNING. This will ensure the batteries are at their optimum charge prior to returning the vehicle
to service.
ý WARNING
• The charger plug must be pulled slowly from the receptacle. Jerking or pulling the DC cord
out quickly could cause arcing and burning that could damage the plug and receptacle and
could cause batteries to explode.
BATTERY WARNING LIGHT
Precedent, PowerDrive, PowerDrive Plus and IQ System vehicles feature a dash mounted battery 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 shut-off occurs after 16 hours of operation, or 4) charger
malfunctions, the warning light 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 DC 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 that it must be charged to completion as soon as possible.
•The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals (25 seconds,
at 10 second intervals for Precedent vehicles), if the charger times out at 16 hours and the batteries are
not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries should be
checked by your Club Car distributor/dealer.
•The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals (25 seconds,
at 10 second intervals for Precedent vehicles), during a charge cycle (with the DC plug still connected)
if AC power to the charger is interrupted. The light will go out when AC power is restored.

POWERDRIVE CHARGER (EXTERNAL) The Charge Circuit
2005 Domestic Battery Charger Maintenance and Service Manual Page 3-3
3
THE CHARGE CIRCUIT
The vehicle charge circuit consists of the following:
•charger receptacle
•receptacle fuse link
•onboard computer
•batteries
The negative terminal of the receptacle is connected to the onboard computer. The 10-gauge black wire from
the onboard computer connects to the B– terminal on the speed controller, and the 6-gauge black wire (also
on the controller B– terminal) goes through the onboard computer and connects to the negative (–) post of
battery no. 6. The positive terminal of the charger receptacle is connected to the positive (+) 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, the sense lead fuse (on all vehicles except Precedent vehicles), and the 18-gauge gray wire from the
onboard computer. On all vehicles except Precedent vehicles, also check connections of the fuse link located
on the charger receptacle (Figure 3-2, Page 3-3 or Figure 3-3, Page 3-4).
Figure 3-2 Charge Circuit and Battery Configuration – DS, Turf 1, Carryall 1 and DS Villager 4 Vehicles
1
2
3
4
6
5
B–
B -
RED TO
POSITIVE
TERMINAL
TO SOLENOID
TERMINAL
BLACK TO
NEGATIVE
TERMINAL
#10 RED
#10 BLACK
#18 GRAY
#18 GRAY
#6 BLACK
#10 BLACK
FUSE LINK
#10 BLACK
SOLID STATE SPEED CONTROLLER
ONBOARD
COMPUTER
CHARGER
RECEPTACLE
SENSE LEAD FUSE
(Speed controller for IQ System will have
different appearance.)

POWERDRIVE CHARGER (EXTERNAL) The Charge Circuit
Page 3-4 2005 Domestic Battery Charger Maintenance and Service Manual
3
Figure 3-3 Charge Circuit and Battery Configuration – Turf 2, Carryall 2 and Villager 6 and 8 Vehicles
Figure 3-4 Charge Circuit and Battery Configuration – Precedent Vehicles
#6 RED
1
2
3
4
6
5
B–
TERMINAL
B–
#10 RED
#10 BLACK
#18 GRAY
#18 GRAY
#6 BLACK
#10 BLACK
FUSE LINK
#10 BLACK
SOLID STATE
SPEED CONTROLLER
ONBOARD
COMPUTER
CHARGER
RECEPTACLE
SENSE LEAD FUSE
S1
S2
B+
M–
B–
1
2
3
4
#10 BLACK
#6 RED
#6 BLACK
#6 BLACK
#6 BLACK
BATTERY
BANK
#10 BLACK
#10 RED
#18 GRAY
ONBOARD
COMPUTER
FRONT
OF VEHICLE
SINGLE
POSITION
CONNECTOR
CHARGER
RECEPTACLE
SOLID STATE
SPEED CONTROLLER
TO SOLENOID