Club Car 2008 Export Battery Charger Manual

2008 MAINTENANCE & SERVICE MANUAL
Manual No. 103373122 Edition Code 0408A00000
&
BATTERY CHARGERS
EXPORT
®

2008 Export 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 export Club Car battery chargers,
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.
Copyright © 2007 Club Car, Inc.
Club Car and PowerDrive are registered
trademarks of Club Car, Inc.
This manual effective August 6, 2007.

Page ii 2008 Export 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 supplement. 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.

2008 Export 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
Battery Charger Specifications ......................................................................................................... 2-1
Battery Charger Identification ........................................................................................................... 2-6
SECTION 3 – EXPORT POWERDRIVE BATTERY CHARGER (EXTERNAL)
General Information .......................................................................................................................... 3-1
PowerDrive 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
Limo – 6 x 8-Volt ........................................................................................................................... 3-7
Charger Installation and Operation ................................................................................................... 3-9
AC Power Connection .................................................................................................................. 3-10
Charging Batteries ........................................................................................................................ 3-11
Testing Charger Operation ........................................................................................................... 3-12
DC Cord and Plug Inspection ....................................................................................................... 3-12
Checking Battery Condition After a Charge Cycle ............................................................................ 3-14
Start Charge Cycle ....................................................................................................................... 3-14
Troubleshooting ................................................................................................................................ 3-14
Test Procedures ............................................................................................................................... 3-18
Index of Test Procedures .............................................................................................................. 3-18