Club car 2008-2011 Manual

Manual Number 103373121

Edition Code 0408D1010C

Domestic PowerDrive, IQ Plus and

High Frequency Battery Chargers

2008-2011 Domestic

Battery Charger

Maintenance and Service

Manual

AFTER CHARGERTURNS OFF DISCONNECT DC PLUG BY GRASPING PLUG

BODYAND PULLING PLUG SLOWLYSTRAIGHT OUT OF RECEPTACLE.

MONITORAMMETER FOR CORRECT CHARGE RATE. INITIAL CHARGE RATE WILL

VARYFROM 10 TO 15 AMPS AND THEN TAPER TO AFINISH RATEOF LESS THAN

5AMPS IF BATTERIESARE GOOD. CHARGER SHUTS OFF AUTOMATICALLY

WHENBATTERIES ARE CHARGED.

CONNECTDC PLUG TO RECEPTACLE. CHARGER WILL STARTAUTOMATICALLY

IN2 TO 10SECONDS.

CONNECTAC SUPPLYCORD TO APROPERLYGROUNDED, THREE WIRE OUTLET

OFTHE PROPER VOLTAGE AND FREQUENCYAS SHOWN ON CHARGER.

OUTPUT LEAD POLARITY :POSITIVE;“+”, RED. NEGATIVE; “-”, BLACK. SENSE; BLUE.

MODEL:26560

ACINPUT

:120V

,9.5A, 60HZ

DCOUTPUT

:48V,13A

MODEL:26560

ACINPUT

:120V

,9.5A,60HZ

DCOUTPUT

:48V,13A

MADE IN USA

USPATENTS 6,087,80

5&6,114,833

PATENTPENDING

USPATENTS 6,087,805&6,1

14,833

PATENTPENDING

LISTED 536R

INDUSTRIAL

BATTERYCHARGER

E52338221

LISTED 536R

INDUSTRIAL

BATTERYCHARGER

E52338221

Club Car

2008-2011 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, 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 service manuals, and

other service publications also represent Club Car’s continuing commitment to customer support.

Club Car offers a full line of training and continuing education classes for technicians who want to learn more

about our products. For more information, contact your local dealer or Club Car’s Technical Services depart-

ment for a list of upcoming classes.

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, LLC; P.O. Box 204658; Augusta, Georgia 30917; Attention: Technical Services.

Club Car and PowerDrive are registered

trademarks of Club Car, LLC.

This manual effective August 6, 2007.

Page ii 2008-2011 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, LLC 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, LLC 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, LLC, P.O. Box 204658, Augusta, GA 30917-4658,

USA, Attention: Warranty Administration.

2008-2011 Domestic Battery Charger Maintenance and Service Manual Page iii

CONTENTS

SECTION 1 – SAFETY

General Warning ............................................................................................................................... 1-1

Disabling The Vehicle ................................................................................................................... 1-3

Disconnecting The Batteries ......................................................................................................... 1-3

Connecting The Batteries ............................................................................................................. 1-4

SECTION 2 – CHARGER IDENTIFICATION AND SPECIFICATIONS

Battery Charger Identification ........................................................................................................... 2-1

Specifications .................................................................................................................................... 2-2

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

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 Battery Condition After a Charge Cycle ............................................................................ 3-12

Start Charge Cycle ....................................................................................................................... 3-12

Troubleshooting ................................................................................................................................ 3-12

Test Procedures ............................................................................................................................... 3-16

Index of Test Procedures .............................................................................................................. 3-16

Page iv 2008-2011 Domestic Battery Charger Maintenance and Service Manual

Charger Repairs ............................................................................................................................... 3-27

DC Cord ....................................................................................................................................... 3-27

Heatsink ....................................................................................................................................... 3-28

Transformer .................................................................................................................................. 3-29

Ammeter ....................................................................................................................................... 3-30

Fuse Link ...................................................................................................................................... 3-31

Voltage Suppressor ...................................................................................................................... 3-31

Charger Relay .............................................................................................................................. 3-32

Charger AC Circuit Breaker .......................................................................................................... 3-32

Charger AC Cord .......................................................................................................................... 3-32

Charging a Battery Pack that has Low Voltage ................................................................................ 3-34

SECTION 4 – POWERDRIVE CHARGER (ONBOARD)

General Information ......................................................................................................................... 4-1

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 .............................................................................. 4-29

Retractable AC Cord Reel ............................................................................................................ 4-30

Charging a Battery Pack that has Low Voltage ................................................................................ 4-31

Onboard Charger Removal and Installation ..................................................................................... 4-33

DS Villager 4 ................................................................................................................................ 4-33

Precedent Vehicles ...................................................................................................................... 4-34

2008-2011 Domestic Battery Charger Maintenance and Service Manual Page v

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

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 Battery Charger Features ....................................................................................... 6-2

Battery Warning Light ................................................................................................................... 6-2

The Charge Circuit ............................................................................................................................ 6-3

DS, 800, 810 and 850 Vehicles – 4 x 12-Volt ............................................................................... 6-3

Turf 1 and Carryall 1 Vehicles – 6 x 8-Volt ................................................................................... 6-4

Precedent Vehicles – 4 x 12-Volt .................................................................................................. 6-5

Precedent Vehicles – 6 x 8-Volt .................................................................................................... 6-6

Charger Installation and Operation .................................................................................................. 6-8

AC Power Connection .................................................................................................................. 6-9

Charging Batteries ........................................................................................................................ 6-9

Testing Charger Operation ........................................................................................................... 6-11

DC Cord and Plug Inspection ....................................................................................................... 6-11

Checking Battery Condition After a charge Cycle ............................................................................ 6-12

Start Charge Cycle ....................................................................................................................... 6-12

Troubleshooting ............................................................................................................................... 6-12

Test Procedures ............................................................................................................................... 6-16

Index of Test Procedures ............................................................................................................. 6-16

Charger Repairs ............................................................................................................................... 6-27

DC Cord ....................................................................................................................................... 6-27

Rectifier ........................................................................................................................................ 6-28

Transformer .................................................................................................................................. 6-29

Ammeter ....................................................................................................................................... 6-30

Fuse Link ...................................................................................................................................... 6-31

Relay Board Assembly ................................................................................................................. 6-32

Charger AC Circuit Breaker .......................................................................................................... 6-32

Charger AC Cord .......................................................................................................................... 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 Operation .................................................................................................. 7-8

AC Power Connection .................................................................................................................. 7-9

Charging Batteries ........................................................................................................................ 7-9

Testing Charger Operation ........................................................................................................... 7-11

DC Cord and Plug Inspection ....................................................................................................... 7-11

Checking Battery Condition After a charge Cycle ............................................................................ 7-12

Start Charge Cycle ....................................................................................................................... 7-12

Troubleshooting ............................................................................................................................... 7-12

Test Procedures ............................................................................................................................... 7-16

Index of Test Procedures ............................................................................................................. 7-16

2008-2011 Domestic Battery Charger Maintenance and Service Manual Page vii

Charger Repairs ............................................................................................................................... 7-28

DC Cord ........................................................................................................................................ 7-28

Diode/Heatsink ............................................................................................................................. 7-29

Transformer .................................................................................................................................. 7-30

Ammeter ....................................................................................................................................... 7-31

Fuse Link ...................................................................................................................................... 7-32

Relay Board Assembly ................................................................................................................. 7-32

Charger AC Circuit Breaker .......................................................................................................... 7-32

Charger AC Cord .......................................................................................................................... 7-33

Charging a Battery Pack that has Low Voltage ................................................................................ 7-34

SECTION 8 – IQ PLUS CHARGER (EXTERNAL)

General Information .......................................................................................................................... 8-1

IQ Plus External Charger Features ............................................................................................... 8-2

Battery Warning Light ................................................................................................................... 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 ............................................................................................................................... 8-23

DC Cord ........................................................................................................................................ 8-23

Heatsink ........................................................................................................................................ 8-24

Transformer .................................................................................................................................. 8-25

Ammeter ....................................................................................................................................... 8-26

Fuse Link ...................................................................................................................................... 8-27

Voltage Suppressor ...................................................................................................................... 8-27

Charger Relay ............................................................................................................................... 8-28

Charger AC Circuit Breaker .......................................................................................................... 8-28

Charger AC Cord .......................................................................................................................... 8-28

Charging a Battery Pack that has Low Voltage ................................................................................ 8-29

Page viii 2008-2011 Domestic Battery Charger Maintenance and Service Manual

SECTION 9 – IQ PLUS CHARGER (ONBOARD)

General Information ......................................................................................................................... 9-1

IQ Plus Onboard Charger Features ............................................................................................. 9-2

Battery Warning Light ................................................................................................................... 9-2

UL and CSA Listing ...................................................................................................................... 9-2

The Charge Circuit ........................................................................................................................... 9-2

Onboard Charger Operation ............................................................................................................ 9-3

Onboard Charger AC Power Connection ..................................................................................... 9-4

Charging Batteries ........................................................................................................................ 9-4

Checking Battery Condition with an Onboard Charger .................................................................... 9-5

Start Charge Cycle ....................................................................................................................... 9-5

Testing Charger Operation ........................................................................................................... 9-6

Troubleshooting ............................................................................................................................... 9-6

Test Procedures ............................................................................................................................... 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)

General Information ......................................................................................................................... 10-1

Features ....................................................................................................................................... 10-2

UL and CSA Listing ...................................................................................................................... 10-2

CE Compliance ............................................................................................................................ 10-2

IP (Ingress Protection) Rating ...................................................................................................... 10-2

How To Identify Charge Algorithm Number .................................................................................. 10-3

The Charge Circuit ........................................................................................................................... 10-4

Onboard Charger Operation ............................................................................................................ 10-4

Charger Displays .......................................................................................................................... 10-6

AC Power Connection .................................................................................................................. 10-7

Charging Batteries ........................................................................................................................ 10-7

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