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.
4.
3.
1.
2.
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
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
10
LISTED 536R
INDUSTRIAL
BATTERYCHARGER
E52338221
10
By
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.
Copyright © 2007, 2009, 2010 Club Car, LLC
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

2008-2011 Domestic Battery Charger Maintenance and Service Manual Page ix
Maintenance ..................................................................................................................................... 10-8
Troubleshooting ................................................................................................................................ 10-9
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 x 2008-2011 Domestic Battery Charger Maintenance and Service Manual

2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing 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 2008-2011 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.
• 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.
• After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
• All electric vehicles:
To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-1,
Page 1-4 thru Figure 1-8, Page 1-5).
• 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.
• If battery wire terminals are damaged or corroded, they should be replaced or cleaned as
necessary. Failure to do so may cause them to overheat during operation and could result in a
fire, property damage, or personal injury.
WARNING CONTINUED ON NEXT PAGE...

SAFETY General Warning
2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 1-3
1
ý WARNING
• IQ Plus vehicles:
- Use only 4-gauge (AWG) wires with low-resistance terminals to replace battery wires on IQ
Plus models.
- Only IQ Plus chargers should be used with IQ Plus vehicles. Long-term use of a PowerDrive
battery charger with IQ Plus vehicles will damage the batteries.
• 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.
• 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 4-33.
• 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.
ý CAUTION
• Be sure to check the batteries and charger monthly to maintain correct battery water level and
ensure the charger is operating correctly during storage.
DISABLING THE VEHICLE
1. Set the park brake.
2. Turn the key switch OFF and remove the key.
3. Place the Forward/Reverse control in the NEUTRAL position.
4. In addition, chock the wheels if servicing or repairing the vehicle.
DISCONNECTING THE BATTERIES
1. Disable the vehicle. See Disabling The Vehicle on page 1-3.
2. 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.
3. Disconnect the batteries, negative (–) cable first, as shown (Figure 1-1 through Figure 1-8).
4. After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.

SAFETY General Warning
Page 1-4 2008-2011 Domestic Battery Charger Maintenance and Service Manual
1
CONNECTING THE BATTERIES
1. Ensure the Tow/Run switch is in the TOW position.
2. Connect the battery cables, positive (+) cable first.
3. Tighten battery terminals to 110 in-lb (12.4 N·m).
4. Coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to minimize corrosion..
Figure 1-1 Precedent Battery Configuration – Style A
4 x 12-Volt Batteries
Figure 1-2 Precedent Battery Configuration – Style B
4 x 12-Volt Batteries
(Viewed 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.
(Viewed 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 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.
(Viewed 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.
12
3
4
RUN
TOW
3
2
1
(+)
(–)
(+)
2
1
POS
NEG
POS
NEG
2
4
1
3
POS
POS
NEG
NEG
(–)
3
TOW
RUN
2
3
4
5
6
+
1
1
(–)
(+)
3
2
1
2
3
4
3
2
1
(–)
(+)

SAFETY General Warning
2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 1-5
1
Figure 1-5 Turf1 and Carryall 1 Battery Configuration Figure 1-6 Turf 2 and 252/Carryall 2 and 252/ XRT 900
IQ Plus and Carryall 6 IQ Plus (Style B) Battery Config-
uration
(Viewed 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.
(Viewed 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 1-7 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 negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.
(Viewed 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.
3
2
(+)
(–) 1
2
3
4
6
5
1
1
3
5
7
8
2
4
6
3
2
1
(+)
(–)
1
3
5
7
8
2
4
6
2
(+)
3
1
(–)
8
74
5
6
13
2
3
2
1

1

2008-2011 Domestic Battery Charger Maintenance and Service Manual Page 2-1
2
SECTION 2 – CHARGER IDENTIFICATION AND
SPECIFICATIONS
BATTERY CHARGER IDENTIFICATION
There are several different 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. 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, repairing and/or replacing 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.
CHARGER NAME CHARGER
MODEL (PART NUMBER) REFER TO
PowerDrive(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 (103394402)
26560-19 (103394403)
Section 6 – PowerDrive 3 – Model 26560
26580-11 (103499101)
26580-18 (103499102)
26580-19 (103499103)
Section 7 – PowerDrive 3 – Model 26580
IQ Plus(external)
25730-11 (102847801)
25730-18 (102847802)
25730-19 (102847803)
Section 8 – IQ Plus Charger (External)
IQ Plus(onboard) 25260-11 (102837001)
25260-50 (103772401) Section 9 – IQ Plus Charger (Onboard)
High Frequency 912-4852 (SVPP325510)
algorithm #11 Section 10 – High Frequency Charger (Onboard)
High Frequency 912-4852 (SVPP325511)
algorithm #26 Section 10 – High Frequency Charger (Onboard)
High Frequency 912-4852 (SVPP325512)
algorithm #125 Section 10 – High Frequency Charger (Onboard)

CHARGER IDENTIFICATION AND SPECIFICATIONS Specifications
Page 2-2 2008-2011 Domestic Battery Charger Maintenance and Service Manual
2
SPECIFICATIONS
POWERDRIVE EXTERNAL
CHARGER SPECIFICATIONS PowerDrive Battery Charger
Model number
(CC P/N) 17930-11 (101802201) 17930-18 (101802202) 17930-19 (101802203)
AC input
AC voltage: 105-128 VAC (acceptable range) • • •
Frequency: 60 Hz. • • •
Power consumption
Max. AC current (amps) 10.71 10.71 10.71
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 9.0 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.
(274.3 cm)
DC cord length 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)
Mounting configuration
Mounting: Set on shelf, wall mount with keyhole, or hang securely
from ceiling. •••