Club Car 2008 Export Battery Charger, Maintenance Service Manual

Page 1: ...2008 MAINTENANCE SERVICE MANUAL Manual No 103373122 Edition Code 0408A00000 BATTERY CHARGERS EXPORT ...

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Page 3: ... 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 fo...

Page 4: ...rove 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 ma...

Page 5: ...rmation 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 Cond...

Page 6: ...er Features 4 2 Battery Warning Light 4 2 The Charge Circuit 4 2 Charger Operation 4 4 AC Power Connection 4 4 Normal Charger Operation 4 5 Testing Charger Operation 4 6 Checking Battery Condition 4 8 Troubleshooting 4 8 Test Procedures 4 11 Index of Test Procedures 4 11 Charger Repairs 4 26 DC Cord 4 26 Heatsink 4 27 Transformer 4 28 Ammeter 4 29 Fuse Link 4 30 Charger Relay 4 30 Charger AC Circu...

Page 7: ...ing 5 10 Test Procedures 5 14 Index of Test Procedures 5 14 Charger Repairs 5 27 DC Cord 5 27 Heatsink 5 28 Transformer 5 29 Ammeter 5 30 Fuse Link 5 31 Voltage Suppressor 5 31 Charger Relay 5 32 Charger AC Circuit Breakers 5 32 AC Charger Receptacle 5 33 Charging a Battery Pack that has Low Voltage 5 34 SECTION 6 EXPORT IQ PLUS CHARGER ONBOARD General Information 6 1 IQ Plus Onboard Charger Featu...

Page 8: ...res 6 10 Charger Repairs 6 24 DC Cord 6 24 Heatsink 6 25 Transformer 6 26 Ammeter 6 27 Fuse Link 6 28 Charger Relay 6 28 Charger AC Circuit Breaker 6 29 Charger AC Cord and Retractable Cord Reel 6 29 Charging a Battery Pack that has Low Voltage 6 31 Onboard Charger Removal and Installation 6 34 SECTION i INDEX ...

Page 9: ...uld 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...

Page 10: ...eme 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...

Page 11: ...sary Failure to do so may cause them to overheat during operation and could result in a fire property damage or personal injury 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 Li...

Page 12: ...e 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 and 850 12 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 b...

Page 13: ...es 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order Figure 1 7 Transporter 4 and 6 and Carryall 6 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 pos...

Page 14: ... 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 STORAGE RUN Switch in STORAGE before disconnecting or connecting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse or...

Page 15: ...e acceptable range at 200 VAC setting 190 210 190 210 AC voltage acceptable range at 220 VAC setting 209 231 209 231 AC voltage acceptable range at 240 VAC setting 228 252 228 252 Frequency 50 Hz 60 Hz POWER CONSUMPTION Max AC current amps at 100 VAC 50 Hz 13 6 13 6 Max AC current amps at 100 VAC 60 Hz 12 4 12 4 Max AC current amps at 200 VAC 50 Hz 6 9 6 9 Max AC current amps at 200 VAC 60 Hz 6 3 ...

Page 16: ...8 252 228 252 228 252 Frequency 50 Hz 60 Hz POWER CONSUMPTION Max AC current amps at 100 VAC 50 Hz 13 6 13 6 13 6 13 6 Max AC current amps at 100 VAC 60 Hz 12 4 12 4 12 4 12 4 Max AC current amps at 200 VAC 50 Hz 6 9 6 9 6 9 6 9 Max AC current amps at 200 VAC 60 Hz 6 3 6 3 6 3 6 3 Max AC current amps at 220 VAC 50 Hz 6 9 6 9 6 9 6 9 Max AC current amps at 220 VAC 60 Hz 6 3 6 3 6 3 6 3 Max AC curre...

Page 17: ...able 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 9 5 in 24 cm Weight 37 lb 16 8 kg 37 7 lb 17 1 kg 38 2 lb 17 3 kg 37 lb 16 8 kg MOUNTING CONFIGURATION Mounting Onboard secured to the vehicle EXPORT POWERDRIVE ONBOARD CHARGER SPECIFICATIONS Export PowerDrive Onboard Battery Charger Model number CCI P N 17790 10 101831601 17790 11 101831602 17790 12 1...

Page 18: ...0 Max AC current amps at 100 VAC 60 Hz 14 6 14 6 Max AC current amps at 200 VAC 50 Hz 7 6 7 6 Max AC current amps at 200 VAC 60 Hz 7 4 7 4 Max AC current amps at 220 VAC 50 Hz 7 0 7 0 Max AC current amps at 220 VAC 60 Hz 6 7 6 7 Max AC current amps at 240 VAC 50 Hz 6 4 6 4 Max AC current amps at 240 VAC 60 Hz 6 1 6 1 DC OUTPUT DC voltage VDC start of charge cycle 48 48 DC current amps start of cha...

Page 19: ...N Max AC current amps at 100 VAC 50 Hz 16 0 Max AC current amps at 100 VAC 60 Hz 14 6 Max AC current amps at 200 VAC 50 Hz 7 6 Max AC current amps at 200 VAC 60 Hz 7 4 Max AC current amps at 220 VAC 50 Hz 7 0 Max AC current amps at 220 VAC 60 Hz 6 7 Max AC current amps at 240 VAC 50 Hz 6 4 Max AC current amps at 240 VAC 60 Hz 6 1 DC OUTPUT DC voltage VDC start of charge cycle 48 DC current amps st...

Page 20: ...TTERY CHARGER NAME AND MODEL NUMBER REFER TO Export PowerDrive External Battery Charger 18780 11 101831503 Section 3 Export Power Drive Battery Charger Exter nal Export PowerDrive External Battery Charger 18780 18 101831504 Export PowerDrive Onboard Battery Charger 17790 10 101831601 Section 4 Export Power Drive Charger Onboard Export PowerDrive Onboard Battery Charger 17790 11 101831602 Export Po...

Page 21: ...t 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 See following NOTE NOTE At one hour and at two hours into th...

Page 22: ... features 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 ...

Page 23: ...e charger receptacle is connected to the pos itive 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 g...

Page 24: ...e is connected to the pos itive 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...

Page 25: ... computer and connects to the negative post of battery no 4 The positive terminal of the charger recepta cle is connected to the positive post of battery no 1 The gray wire from the onboard computer is con nected to the charger receptacle 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 wire continuity ...

Page 26: ...tive post of battery no 6 The positive terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the charger recepta cle 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 wire continuity and connections between the charge...

Page 27: ...ve terminal of the charger receptacle is connected to the pos itive post of battery no 1 The gray wire from the onboard computer is connected to the charger recepta cle 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 ...

Page 28: ...ry Charger Maintenance and Service Manual 3 Figure 3 7 Charge Circuit and Battery Configuration Limo Electric Vehicles 1 2 3 4 6 5 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 ...

Page 29: ...e 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 Each charger should ha...

Page 30: ...O R E C O N N E C T IN G IN P U T C O R D T O S O C K E T O U T L E T C O N N E C T IN P U T P O W E R C O R D T O A P R O P E R LY G R O U N D E D T H R E E W IR E S O C K E T O U T L E T W IT H 5 0 O R 6 0 H Z F R E Q U E N C Y A N D M E A S U R E D M A IN S IN P U T V O LT A G E M AT C H IN G T H E S W IT C H S E T T IN G O U T P U T L E A D P O L A R IT Y R E D N E G AT IV E B L A C K S E N S ...

Page 31: ...receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 3 8 Page 3 10 Do not pull on the DC cord Figure 3 9 Page 3 10 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straigh...

Page 32: ...e been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CCI P N 101831801 See Communication Display Module CDM in Section...

Page 33: ... Removal on page 3 30 See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately Figure 3 11 PowerDrive Export Charger Wiring Diagram BLACK BLACK 6 DC CORDSET RED RED BLUE BLACK BLACK BLACK AC CIRCUIT BREAKERS AC CORD GRN YEL TAN TAN DIODES WITH HEATSINK AMMETER TRANSFORMER RELAY PRIMARY COIL SECONDARY COIL RED BLUE 9 7 6 4 CASE GROUND VOLT...

Page 34: ...le should be approximately 59 to 63 volts DC while the charger is still operating START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle charger receptacle 2 Wait 20 seconds then reconnect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the batteries ...

Page 35: ...service manual Poor connection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 21 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Tes...

Page 36: ... or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 3 26 Failed transformer or voltage switch Test Procedure 6 Transformer on page 3 24 Incorrect charger wiring Check battery charger wiring Incorrect AC voltage selector switch position Check switch position for proper incoming AC voltage selection Battery warning light illuminates for ten seconds at four second inte...

Page 37: ... 2008 Export Battery Charger Maintenance and Service Manual Page 3 17 3 Figure 3 12 PowerDrive Battery Charger Export Exploded View R C lub C ar PRIMARY COIL DC CORD SECONDARY COIL DIODE AND HEATSINK RELAY FUSE AND LENS ASSEMBLY AMMETER TRANSFORMER 16 13 9 21 ...

Page 38: ...ht prevent a sound electrical connection 2 Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 DS DS Villager 4 Turf 1 Carryall 1 800 810 850 and Limo vehicles Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figu...

Page 39: ...age 4 1 DS DS Villager 4 800 810 and 850 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 3 14 Page 3 19 4 2 Turf 1 Carryall 1 and Limo With a multimeter set to 200 volts DC measure the voltage of the bat tery pack between the positive post of battery no 1 and the negative post of ba...

Page 40: ...ly bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 3 37 Figure 3 17 Battery Voltage Test Precedent Style A Battery Configuration Figure 3 18 Battery Voltage Test Precedent Style B Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 4 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK ...

Page 41: ...akers on the front of the charger and reset if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC wall outlet voltage should be within the range specified in the following chart If proper voltage is not present and the voltage selector switch is set for the correct vol...

Page 42: ...Procedure 4B Both Diodes Failed on page 3 23 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 A single diode failure is indicated by the failure of one fuse link closed circuit diode or by the charger output being low open circuit diode If a diode has failed the entire heatsink must be replaced To check diodes 1 Disconnect AC cord fro...

Page 43: ...be replaced To determine why both diodes failed 1 Check the batteries and the receptacle to ensure that they are wired in the correct polarity Figure 3 2 Page 3 3 through Figure 3 7 Page 3 8 Also check the voltage and polarity at the receptacle 2 Make sure the charger is wired correctly the DC cord red wire should be connected to the center terminal of the heatsink the DC cord blue wire should be ...

Page 44: ...n the positive and negative pins and middle pin on the DC plug Figure 3 11 Page 3 13 There should be no continuity TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns If the transformer has failed the ammeter will indicate low output or no output however th...

Page 45: ...9 Connect the AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced 10 If the voltage reading is normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuit...

Page 46: ...al part of the charger Figure 3 26 Page 3 26 4 Disconnect brown wire 1 of AC cord from charger relay terminal 6 5 Disconnect the blue wire 4 from the charger relay terminal 4 6 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the brown wire 1 Test for continuity on each of the flat blades and on the round pin of the AC plug The tester should indicate continuity...

Page 47: ... tester should indicate no con tinuity If tester indicates continuity the DC cord must be replaced 9 Place the continuity test probe on the unmarked middle pin of the DC plug The tester should indicate no continuity If tester indicates continuity the DC cord must be replaced 10 Move the continuity tester clip to the black wire of the DC cord 11 Place the continuity test probe on the negative pin o...

Page 48: ...let and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove the transformer tan secondary coil wire from the upper terminal of the heatsink Figure 3 11 Page 3 13 4 Remove the other transformer tan secondary coil wire from the bottom terminal of the heatsink and place the continuity test clip on the ammeter buss bar Figure 3 12 Page 3 17 Test for continuity between the buss bar ...

Page 49: ...nuity If tester indicates continuity the relay contacts have failed closed and the relay must be replaced 4 Remove the blue wire from terminal 4 of the relay and black wire from terminal 7 of the relay Figure 3 11 Page 3 13 Place continuity tester leads on terminals 4 and 7 of the relay The tester should indicate no continuity If tester indicates continuity the relay contacts have failed closed an...

Page 50: ...NING 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 3 28 Page 3 30 4 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink 5 Disconnect the DC cord blue wire from the blue wire of the voltage suppressor assembly connected to the relay c...

Page 51: ... mounting screws starting with the bottom holes Tighten the screws to 11 in lb 1 2 N m HEATSINK See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Heatsink Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 3 30 2 Remove the charger cover 3 Remove both secondary coil transformer wires tan from the heatsink Figure 3 1...

Page 52: ...fuse Tighten nut to 22 in lb 2 5 N m 3 Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in lb 2 5 N m 4 Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in lb 2 0 N m 5 Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut ...

Page 53: ...the charger Ammeter Installation 1 Place the ammeter in position in the charger face Figure 3 29 Page 3 33 2 Install the nuts 2 and tighten until ammeter is firmly secured 3 Connect the DC cord black wire 5 to the left as viewed from inside the charger post of the ammeter 4 Connect the buss bar 3 from the fuse link to the right post of the ammeter Place flat washers on both sides of the buss bar 5...

Page 54: ...sformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tighten to 22 in lb 2 5 N m 4 Install the charger cover VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 The voltage suppressor which is incorporated into a wire assembly in t...

Page 55: ... hardware securing relay to relay mounting bracket to 18 in lb 2 0 N m CHARGER AC CIRCUIT BREAKERS See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 AC Circuit Breaker Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 3 30 2 Remove the charger cover 3 Disconnect the two black wires attached to top circuit breaker F...

Page 56: ...t the AC cord green yellow wire at the charger base Figure 3 11 Page 3 13 6 Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger AC Cord Installation 1 Insert the brown blue and green yellow leads of the new AC cord into the charger through the hole in the charger face Figure 3 11 Page 3 13 2 Connect the brown wire to terminal 6 at the charger relay...

Page 57: ... terminal Figure 3 31 Page 3 38 4 2 Disconnect the brown wire from relay terminal 6 4 3 Use a jumper wire with alligator clips to connect the black wire from relay terminal 9 to the brown wire from relay terminal 6 Figure 3 31 Page 3 38 4 4 Disconnect the black wire from relay terminal 7 4 5 Disconnect the blue wire from relay terminal 4 4 6 Use a jumper wire with alligator clips to connect the bl...

Page 58: ...he battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual Figure 3 31 Export PowerDrive Charger Wiring Diagram Relay Bypassed BLACK BLACK 6 DC CORDSET RED RED BLUE BLAC...

Page 59: ...with model numbers listed above that are installed in vehicles other than DS and Prece dent vehicles contact your local Club Car dealer or distributor The PowerDrive battery charger is automatic and has no external controls Figure 4 1 Page 4 1 When the AC cord is plugged in there is a 2 to 15 second delay before charging begins The onboard computer OBC records the amount of energy consumed as the ...

Page 60: ...es and will com plete the charge during the next charge cycle When the charger AC 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 t...

Page 61: ...s two wires in the adapter harness One wire connects to the onboard computer The second wire connects to the charger receptacle gray lead wire To check the charge circuit check the connections between the 18 gauge gray wire from the OBC the sense lead fuse DC cord red wire DC cord black wire and the wire connections between the batteries Figure 4 2 Charge Circuit DS Villager 4 Figure 4 3 Charge Ci...

Page 62: ...therwise damaged Make sure it is operating properly before putting it back in use Each charger should have its own 15 or 20 ampere branch circuit protection circuit breaker or fuse in accordance with the National Electrical Code ANSI NFPA 70 and local codes and ordinances Improper AC supply circuit protection may result in a fire Improper connection of the equipment grounding conductor can result ...

Page 63: ...O R E D U C E T H E R IS K O F E L E C T R IC S H O C K C O N N E C T O N LY T O P R O P E R LY G R O U N D E D T H R E E W IR E S O C K E T O U T L E T S A D JU S T T H E IN P U T V O LT A G E S W IT C H L O C AT E D O N T H E B A C K O F T H IS U N IT T O 1 0 0 2 0 0 2 2 0 2 4 0 V T O M AT C H T H E M E A S U R E D IN P U T V O LT A G E B E F O R E C O N N E C T IN G IN P U T C O R D T O S O C K...

Page 64: ... minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf ...

Page 65: ...BLACK BLACK AC CIRCUIT BREAKERS AC CORD CONTROL BOARD GREEN or GREEN YELLOW TAN TAN DIODES WITH HEATSINK AMMETER TRANSFORMER PRIMARY COIL SECONDARY COIL CASE GROUND BLACK or BROWN WHITE or BLUE BLACK BLACK BLACK BLACK 1 BLACK BLACK BLACK BLACK BLACK 1 TAN 1 TAN 6 TAN 1 TAN 6 TAN 5 TAN 4 TAN 3 TAN 2 BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLK BLK BLACK 6 RELAY 9 7 6 4 3 1 A B FUSE 1 2 3 4 5...

Page 66: ... unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the vehicle has been driven even if only a few feet the onboard computer ...

Page 67: ...ible click but no transformer hum and ammeter does not move Improper AC line voltage Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 15 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 15 Failed AC cord reel Test Procedure 8 Continuity on page 4 21 Internal AC breaker Test Procedure 3 AC Power and Continuity Check of AC Circuit o...

Page 68: ...ard on page 4 13 Extremely discharged batteries or cold temperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 4 21 Failed transformer or voltage switch Test Procedure 6 Transformer on page 4 19 Incorrect AC voltage selector sw...

Page 69: ...ck wire from the battery charger at the fuse link on the charger receptacle 1 3 Check the connections of the DC cord blue wire 17 from the charger and the gray wire from the onboard computer to the the 3 way wire adapter 18 Figure 4 29 Page 4 36 See following WARNING ý WARNING Do not bypass the sense lead fuse 1 4 Remove the gray sense lead fuse and check it for continuity with a multimeter set to...

Page 70: ...ecedent only With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 4 Figure 4 7 Page 4 12 or Figure 4 8 Page 4 12 Figure 4 6 Battery Voltage Test DS Villager 4 Figure 4 7 Battery Voltage Test Precedent Style A Battery Configuration Figure 4 8 Battery Voltage Test Precedent Style B Battery Configur...

Page 71: ...tion 1 Page 1 1 DC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and blue wires remain connected to the vehicle All wires remain connected to the control board Set multimeter to 200 volts DC See following DANGER ý DANGER Do not touch any wire or component in the battery charger while DC power is present Failure to heed this warning will result in an electric shock 2 Place black p...

Page 72: ...o terminal from which the white or blue AC cord wire was disconnected Figure 4 11 Page 4 14 4 Connect AC cord to outlet Reading should be input voltage from outlet 5 If reading is incorrect replace control board Figure 4 10 DC Circuit Test Figure 4 11 AC Circuit Test Figure 4 12 Control Board 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX...

Page 73: ...ove the charger cover 5 3 Bypass the relay See Charging a Battery Pack that has Low Voltage on page 4 33 5 4 With relay bypassed there should be continuity across the AC cord blades Figure 4 13 Page 4 16 6 If the circuit is not complete check the wiring of the AC cord AC cord reel transformer primary coil wires 21 internal AC circuit breakers 13 and voltage selector switch 9 Figure 4 5 Page 4 7 7 ...

Page 74: ... diode test function connect the red test probe to the diode mounting plate and the black test probe to a diode terminal and note the reading Figure 4 14 Page 4 17 6 Reverse test probes and check each diode again and note the reading Figure 4 15 Page 4 17 A diode is designed to conduct current in one direction only If a diode conducts current shows continuity in both directions the entire heatsink...

Page 75: ...gure 4 5 Page 4 7 If a reverse polarity connection is made between the charger and the batteries both fuse links will blow when the DC cord is connected to the vehicle whether or not the AC cord is plugged into an outlet 3 Make sure the charger is wired to the vehicle correctly the DC cord red wire should be connected to the same large post as the 6 gauge red wire connected to the positive post of...

Page 76: ...erse the test probes and check the DC cord again Figure 4 17 Page 4 18 The circuit should show continuity in only one direction 8 If the circuit does not show continuity in either direction and the charger fuse is not blown individually check all connections and the continuity of the DC cord and ammeter See Test Procedure 8 Conti nuity on page 4 21 Also check the diodes heatsink See Test Procedure...

Page 77: ...ransformer may be caused by aging or a short circuit in adjacent coil turns If the transformer has failed the ammeter will indicate low output or no output however the transformer may hum A blown AC line fuse or tripped AC circuit breaker in the charger or the storage facility may be caused by an improperly wired charger an improper setting of the AC voltage selector switch or a failed transformer...

Page 78: ...nd properly connect relay wiring See following WARNING ý WARNING The relay wiring must be properly connected prior to placing the charger back into normal service Failure to remove the jumper wire and properly connect the relay wiring could result in property damage severe personal injury or death TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 1 With the batte...

Page 79: ...ed the short AC cord and retractable cord reel must be tested independently of each other 9 Place the red probe on the white or blue wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug on the retractable cord reel The tester should indicate continuity on only one flat blade If any other reading is obtained the short AC cord and retractable cord reel must be tes...

Page 80: ... Continuity Test Figure 4 20 Heatshrink Removal Figure 4 21 Short AC Cord Test 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 200 OHM SETTING 4 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 200 OHM SETTING 4 ...

Page 81: ...ctable cord reel at the same time 1 Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 3 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 4 20 Page 4 22 4 Disconnect the short AC cord from the retractable cord reel 5...

Page 82: ...ty on each of the wires on the other end of the DC cord The tester should indicate continuity on the blue DC cord wire only If any other reading is obtained the DC cord must be replaced 8 Place the red probe on the black wire of the DC cord Test for continuity on each of the wires on the other end of the DC cord The tester should indicate continuity on the black DC cord wire only If any other read...

Page 83: ...er leads on terminals 4 and 7 of the relay The tester should indicate no continuity If tester indicates continuity the relay contacts have failed closed and the relay must be replaced 5 Connect charger DC cord to batteries Figure 4 6 Page 4 12 through Figure 4 9 Page 4 13 Use jumper wires if necessary The tester should indicate continuity on relay terminals 6 and 9 and terminals 4 and 7 If tester ...

Page 84: ... and remove the battery charger from the vehi cle See Onboard Charger Removal on page 4 35 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 4 24 Page 4 27 4 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink 5 Remove the wire tie that ...

Page 85: ...moval 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 See preceding WARNING 2 Remove the charger cover 3 Remove both secondary coil transformer wires tan from the heatsink Figure 4 18 Page 4 20 and remove the two red wires from the heatsink 4 Remove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Plac...

Page 86: ...fuse 7 Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in lb 3 2 N m 2 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in lb 2 5 N m Figure 4 5 Page 4 7 3 Connect...

Page 87: ...y charger from the vehi cle See Onboard Charger Removal on page 4 35 See WARNING on page 4 26 2 Remove the charger cover 3 Using two wrenches to prevent the posts from turning disconnect the DC cord black wire 5 and buss bar 3 from the ammeter Figure 4 25 Page 4 29 4 Remove the two nuts 2 that secure the ammeter to the charger face 5 Remove the ammeter from the face of the charger Ammeter Installa...

Page 88: ...se link assembly Fuse Link Installation 1 Place clear plastic cover over fuse assembly and install mounting screws from front of charger face The center branch of the fuse assembly should be in the upper left corner when viewed from the front of the charger 2 Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 4 25 Page 4 29 Tighten to 22 in lb 2 5 N m 3 Inst...

Page 89: ... Disconnect the two black wires attached to top circuit breaker Figure 4 26 Page 4 31 4 Disconnect the two black wires attached to bottom circuit breaker 5 With a pair of pliers squeeze in the retaining tabs on the sides of the top AC circuit breaker and remove the circuit breaker through the mounting hole in the face of the charger 6 Repeat step 5 for the removal of the bottom circuit breaker AC ...

Page 90: ... charger through the hole in the charger face Figure 4 26 Page 4 31 2 Connect the black wire and white wire to the control board Figure 4 5 Page 4 7 Connect the green wire to the charger base Tighten the screw on the green ground wire terminal to 18 in lb 2 0 N m 3 Position the strain relief bushing on the AC cord 4 Using pliers install the strain relief bushing and AC cord into the mounting hole ...

Page 91: ...relay terminal Figure 4 27 Page 4 34 4 2 Disconnect the black wire from relay terminal 6 4 3 Use a jumper wire with alligator clips to connect the black wire from relay terminal 9 to the black wire from relay terminal 6 Figure 4 27 Page 4 34 4 4 Disconnect the black wire from relay terminal 7 4 5 Disconnect the black wire from relay terminal 4 4 6 Use a jumper wire with alligator clips to connect ...

Page 92: ... battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual Figure 4 27 PowerDrive Onboard Charger Wiring Diagram Relay Bypassed RELAY BYPASS JUMPER WIRE RELAY BYPASS JUMPE...

Page 93: ...35 DS VILLAGER 4 Onboard Charger Removal 1 Disconnect the batteries as instructed See General Warning Section 1 Page 1 1 2 Remove four bolts 21 flat washers 22 lock washers 23 and nuts 24 from charger mounting brack ets Figure 4 28 Page 4 35 3 Remove 10 gauge black charger DC cord wire 19 from the charger receptacle fuse link Figure 4 29 Page 4 36 4 Remove 10 gauge red charger DC cord wire from th...

Page 94: ...and nuts 24 securing charger to chassis and tighten to 108 in lb 12 N m Figure 4 28 Page 4 35 4 Connect battery cables positive cable first and tighten to 144 in lb 16 N m PRECEDENT VEHICLES Onboard Charger Removal 1 Disconnect the batteries as instructed See General Warning Section 1 Page 1 1 2 Disconnect the charger DC cord at the three pin connector 1 Figure 4 30 Page 4 37 3 Remove four bolts 2...

Page 95: ...al Page 4 37 4 Onboard Charger Installation 1 Installation is reverse of removal 2 Install four bolts 2 and nuts 5 securing charger to chassis and tighten to 108 in lb 12 N m 3 Connect battery cables positive cable first and tighten to 110 in lb 12 4 N m Figure 4 30 Onboard Charger Mounting Precedent Vehicles C lu b C ar 5 4 3 2 1 ...

Page 96: ...4 ...

Page 97: ...R E N T IN T IA L C U R R E N T W IL L V A R Y F R O M 13 T O 20 A M P S A N D T H E N TA P E R T O LE S S T H A N 5 A M P S IF B AT T E R IE S A R E G O O D U N IT S H U T S O F F A U T O M AT IC A LL Y W H E N B AT T E R IE S A R E C H A R G E D N O T E D U R IN G P E R IO D S O F E X T E N D E D S T O R A G E T H IS U N IT W IL L C Y C LE B A C K O N T O M A IN TA IN T H E B AT T E R Y IF T H E...

Page 98: ... explode BATTERY WARNING LIGHT IQ Plus 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 charg ing 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 dis...

Page 99: ...tive post of battery no 1 is some times made through another electrical component such as a solenoid or main power fuse 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 charg...

Page 100: ...rd or electrical outlet must accept a three prong plug Extension cord should be a three wire no 12 AWG American Wire Gauge and be as short as possible The use of improper extension cord could result in fire or an electrical shock Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the cha...

Page 101: ... If the battery charger is equipped with a multi position switch for variable AC input voltage the switch must be set for the correct voltage before the AC cord is connected Figure 5 3 Page 5 6 See following CAUTION CAUTION Failure to set the AC input voltage selector switch to the correct voltage could result in damage to the battery charger or batteries NOTE Make sure that the AC cord provided w...

Page 102: ... IN G F O R U S E W IT H C L U B C A R P O W E R D R IV E S Y S T E M 4 8 V E H IC L E S O N LY T O R E D U C E T H E R IS K O F E L E C T R IC S H O C K C O N N E C T O N LY T O P R O P E R LY G R O U N D E D T H R E E W IR E S O C K E T O U T L E T S A D JU S T T H E IN P U T V O LT A G E S W IT C H L O C AT E D O N T H E B A C K O F T H IS U N IT T O 1 0 0 2 0 0 2 2 0 2 4 0 V T O M AT C H T H E...

Page 103: ...program ammeter will drop to zero one hour and two hours into the charge cycle See following NOTE NOTE Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold bat...

Page 104: ...ections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact S...

Page 105: ... the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 2 Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle The charger relay should close with an audible click after a 2 to 15 second delay See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted...

Page 106: ...NING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 5 6 Page 5 9 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Use the following Troubleshooting Guide for troubleshooting export IQ Plus external battery chargers model numbers 25880 11 and 2588...

Page 107: ...onnection at 10 gauge black wire or 18 gauge gray wire at the OBC applicable to Precedent vehicles only Check wire connections Relay closes with an audible click but no transformer hum and ammeter does not move Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 17 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on pa...

Page 108: ... AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 5 22 Failed transformer or voltage switch Test Procedure 6 Transformer on page 5 20 Incorrect charger wiring Check battery charger wiring Incorrect AC voltage selector switch position Check switch position for proper incoming AC voltage selection Battery warning light illuminates for ten seconds at four second interva...

Page 109: ...CHARGER EXTERNAL Troubleshooting 2008 Export Battery Charger Maintenance and Service Manual Page 5 13 5 Figure 5 7 IQ Plus Battery Charger Export Exploded View 1 3 4 10 12 21 14 1 8 6 5 15 19 20 17 18 11 2 17 16 9 13 ...

Page 110: ...ht prevent a sound electrical connection 2 Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Check the wire connections to the charger receptacle 3 1 Carryall 6 Transporter 4 and 6 and Villager 6 and 8 Verify that the 10 gauge red wire from the charger receptacle is connected to the same large post of the solenoid as the 6 gauge ...

Page 111: ... should be less than 2 ohms 4 With a multimeter set to 200 volts DC measure the voltage of the battery pack between the positive post of battery no 1 and the negative post of battery no 8 Figure 5 9 Page 5 16 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC to allow the onboard computer to close the charge...

Page 112: ...LLAGER 6 AND 8 VEHICLES 1 3 5 7 8 2 4 6 1 3 5 7 8 2 4 6 Place multimeter black probe here Place multimeter black probe here Place multimeter red probe here Place multimeter red probe here Place multimeter red probe here Place multimeter black probe here TURF 2 252 VEHICLES CARRYALL 2 252 VEHICLES XRT 900 VEHICLES TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES FRONT OF VEHICLE FRONT OF VEHICLE ...

Page 113: ...not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY TEST OF AC CIRCUIT See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Check the AC circuit breakers on the front of the charger and reset if necessary 3 Check the AC line fuse or circuit breaker in the storage facility 4 With a mu...

Page 114: ...e personal injury or death TEST PROCEDURE 4 DIODES Use Test Procedure 4A Single Diode Failure on page 5 18 for single diode failures and testing of individual diodes If both diodes have failed use Test Procedure 4B Both Diodes Failed on page 5 19 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 A single diode failure is indicated by t...

Page 115: ...s will be blown If both diodes have failed open the relay will close and the trans former will hum but the ammeter will not indicate any output and the AC circuit breakers may trip off If both diodes have failed open or closed the entire heatsink must be replaced To determine why both diodes failed 1 Check the batteries and the receptacle to ensure that they are wired in the correct polarity Figur...

Page 116: ... the charger relay and check continuity between the positive and negative pins and middle pin on the DC plug Figure 5 6 Page 5 9 and Figure 5 7 Page 5 13 There should be no continuity TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns If the transformer ha...

Page 117: ...nd a multimeter set to 500 volts AC connect the multimeter probes to the second ary transformer coil wires 1 and 5 9 Connect the AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced 10 If the voltage reading is normal 86 volts ...

Page 118: ...uity on each of the flat blades and on the round pin of the AC plug The tester should indicate continuity on one flat blade only If any other reading is obtained the AC cord or AC charger receptacle on the front panel may be damaged See AC Cord on page 5 22 See also AC Charger Receptacle on page 5 23 7 Place the red probe on the end of the green yellow wire 2 and with the black probe check for con...

Page 119: ...y other reading is obtained the AC cord has failed and must be replaced AC Charger Receptacle 1 Disconnect the AC cord from the AC receptacle on front of battery charger and the incoming AC outlet Disconnect the battery charger from the vehicle 2 Disconnect black wire from charger relay terminal 4 4 Figure 5 18 Page 5 24 and Figure 5 6 Page 5 9 Figure 5 16 AC Plug and AC Charger Receptacle Continu...

Page 120: ...y other reading is obtained the AC charger receptacle or connecting wires have failed and must be replaced 6 Disconnect black wire from charger relay terminal 8 8 Figure 5 18 Page 5 24 Put the red probe on the black wire 8 and check for continuity on the appropriate pin of the AC charger receptacle The tester should indicate continuity on the ground pin only If any other reading is obtained the AC...

Page 121: ...d must be replaced 12 Place the continuity test probe on the unmarked middle pin of the DC plug The tester should indicate no continuity If tester indicates continuity the DC cord must be replaced 13 Move continuity test probe to the blue wire 18 of the DC cord Check for continuity at the middle pin The tester should indicate continuity If tester does not indicate continuity replace DC cord Transf...

Page 122: ...se lead pin short pin of the DC plug Place the red probe on the positive pin of the DC plug The multimeter should indicate no tone If a tone is emitted indicating a closed circuit then the voltage suppressor has failed and should be replaced See following NOTE NOTE Repeated failure of sense lead fuses is a symptom of a voltage supressor that has failed in a closed condition Relay 1 Disconnect AC c...

Page 123: ...the tester does not indicate continuity replace the ammeter AC Circuit Breaker 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the wires from the AC circuit breaker 4 Place the continuity test probes on the two terminals of the AC circuit breaker The tester should indicate continuity If the tester does not indicate continuit...

Page 124: ...hing on the cord and insert it into the charger base 6 Secure the blue wire to the black wire in the locations noted in step 6 of DC Cord Removal 7 Tie the wires together as they were before the wire tie was removed See following WARNING ý WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or sever...

Page 125: ...e 7 Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 Install the transformer with the secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in lb 3 2 N m Figure 5 7 Page 5 13 2 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in lb 2 5 N m 3 Conne...

Page 126: ...om the vehicle receptacle See WARNING on page 5 27 2 Remove the charger cover 3 Using two wrenches to prevent the posts from turning disconnect the two black wires from the ammeter 17 Figure 5 20 Page 5 30 4 Remove the two nuts 22 that secure the ammeter to the charger face 5 Remove the ammeter from the face of the charger Ammeter Installation 1 Place the ammeter in position in the charger face Fi...

Page 127: ... assembly and ammeter post Figure 5 7 Page 5 13 Tighten to 22 in lb 2 5 N m 3 Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black to the remaining termi nal Tighten to 27 in lb 3 0 N m 4 Install the charger cover VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 ...

Page 128: ... plug from the vehicle receptacle See WARNING on page 5 27 2 Remove the charger cover 3 Disconnect all wires from the relay 00 Figure 5 7 Page 5 13 4 Remove the two screws and nuts attaching relay to the charger case 5 Remove the relay Charger Relay Installation Install in reverse order of removal Connect wires as shown Figure 5 6 Page 5 9 Tighten hardware secur ing relay to charger base to 18 in ...

Page 129: ... 1 Page 1 1 See additional WARNING on page 5 1 AC Charger Receptacle Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 5 27 2 Remove the charger cover 3 Disconnect the two black wires from the AC charger receptacle Figure 5 6 Page 5 9 4 Disconnect the green yellow wire from the AC charger receptacle 5 Press the retaining tabs on the top a...

Page 130: ...al Figure 5 22 Page 5 35 4 2 Disconnect the black wire from relay terminal 4 4 3 Use a jumper wire with alligator clips to connect the black wire from relay terminal 2 to the black wire from relay terminal 4 Figure 5 22 Page 5 35 4 4 Disconnect the black wire from relay terminal 6 4 5 Disconnect the black wire from relay terminal 8 4 6 Use a jumper wire with alligator clips to connect the black wi...

Page 131: ...he DC cord into the charger receptacle then plug the AC cord into an electrical outlet 11 Allow the charger to continue charging the batteries until the charger shuts off automatically 12 When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to de...

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Page 133: ... T IC A L C O N N E C T IO N S T E S T G O O D T H E A M M E T E R IN D IC AT E S IN T IA L C H A R G E R AT E M O N T O R A M M E T E R F O R C O R R E C T C U R R E N T IN T IA L C U R R E N T W IL L V A R Y F R O M 13 T O 20 A M P S A N D T H E N TA P E R T O LE S S T H A N 5 A M P S IF B AT T E R IE S A R E G O O D U N IT S H U T S O F F A U T O M AT IC A LL Y W H E N B AT T E R IE S A R E C H...

Page 134: ...ery 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 fully replenish the batteries and will com plete the charge during the next charge cycle When the charger AC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds if the charge is less...

Page 135: ...lt in an explosion ý WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded th...

Page 136: ...l help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes ONBOARD CHARGER AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Section 2 Charger Identification and Specifica tions If the battery charger is equ...

Page 137: ... O V IN G C O V E R N O S M O K IN G O R N A K E D L IG H T S W A R N IN G F O R U S E W IT H C L U B C A R P O W E R D R IV E S Y S T E M 4 8 V E H IC L E S O N LY T O R E D U C E T H E R IS K O F E L E C T R IC S H O C K C O N N E C T O N LY T O P R O P E R LY G R O U N D E D T H R E E W IR E S O C K E T O U T L E T S A D JU S T T H E IN P U T V O LT A G E S W IT C H L O C AT E D O N T H E B A C...

Page 138: ...rged the battery warning light will illuminate inter mittently See Battery Warning Light on page 6 2 2 If the charger does not operate exactly as described above refer to the wiring diagram and make sure that the vehicle is wired correctly Figure 6 2 Page 6 3 and that the internal charger wiring is correct Figure 6 4 Page 6 6 Figure 6 4 Export IQ Plus Onboard Battery Charger Wiring Diagram BLACK B...

Page 139: ...e charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the vehicle has been driven even if only a few ...

Page 140: ... Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 6 13 Failed AC cord reel Test Procedure 8 Continuity on page 6 18 Internal AC breaker Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 6 13 Transformer primary coil Test Procedure 6 Transformer on page 6 16 Relay Test Procedure 8 Continuity on page 6 18 Relay closes and transformer hums but ammeter does not m...

Page 141: ...mperature Recharge batteries Failed or weak battery See Batteries section in the appropriate maintenance and service manual AC line fuse blows or AC circuit breaker trips AC cord is shorted Test Procedure 8 Continuity on page 6 18 Failed transformer Test Procedure 6 Transformer on page 6 16 Incorrect charger wiring Check battery charger wiring Battery warning light illuminates for ten seconds at f...

Page 142: ...f the solenoid battery side for Carryall 6 Villager and TransPorter vehicles 1 2 Verify the connection of the 10 gauge black wire from the onboard computer to the 10 gauge black wire from the battery charger 1 3 Check the connection of the 18 gauge gray wire from the charger to the onboard computer gray wire 1 4 Turf 2 252 Carryall 2 252 and XRT 900 Only Check the fuse in the 18 gauge gray wire 2 ...

Page 143: ...ER 6 AND 8 VEHICLES 1 3 5 7 8 2 4 6 1 3 5 7 8 2 4 6 Place multimeter black probe here Place multimeter black probe here Place multimeter red probe here Place multimeter red probe here Place multimeter red probe here Place multimeter black probe here TURF 2 252 VEHICLES CARRYALL 2 252 VEHICLES XRT 900 VEHICLES TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES FRONT OF VEHICLE FRONT OF VEHICLE ...

Page 144: ... blue wires remain connected to vehicle Set multimeter to volts AC 2 Disconnect white or blue wire of AC cord at terminal on control board Figure 6 8 Page 6 13 See fol lowing DANGER ý DANGER Do not touch any wire or component in the battery charger while AC power is present Failure to heed this warning will result in an electric shock 3 Place black probe of multimeter set to 500 volts AC onto term...

Page 145: ...m the vehicle See Onboard Charger Removal on page 6 34 5 2 Remove the charger cover 5 3 Bypass the relay See Charging a Battery Pack that has Low Voltage on page 6 31 5 4 With relay bypassed there should be continuity across the AC cord blades Figure 6 9 Page 6 14 6 If the circuit is not complete check the wiring of the AC cord AC cord reel transformer primary coil wires 21 internal AC circuit bre...

Page 146: ...ut being low open circuit diode If a diode has failed the entire heatsink must be replaced To check diodes 1 Disconnect AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 3 Remove the charger cover 4 Disconnect one transformer secondary coil wire from the diode terminal Figure 6 10 Page 6 15 5 Using a low voltage continuity tester or...

Page 147: ...t they are wired in the correct polarity Figure 6 2 Page 6 3 2 Make sure the charger is wired correctly The DC cord red wire should be connected to the center ter minal of the heatsink the DC cord blue wire should be connected to the control board and the DC cord black wire should be connected to the left side of the ammeter when viewed from inside the charger Figure 6 4 Page 6 6 If a reverse pola...

Page 148: ...sed by failed diodes See Test Procedure 4 Diodes on page 6 14 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 6 18 8 Check continuity between the DC cord red black and blue wires Figure 6 4 Page 6 6 There should be no continuity TEST PROCEDURE 6 TRANSFORMER See General Warning Section 1 Page 1 1 Failure of the transformer may be caused by agi...

Page 149: ...ond ary transformer coil tan wires 10 Connect the AC cord to the wall outlet and monitor the multimeter for the secondary coil voltage If mea sured voltage is approximately 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced 11 If the voltage reading is normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wal...

Page 150: ... from the control board 6 Disconnect the AC cord white or blue wire 4 from the control board Figure 6 13 Page 6 19 7 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black or brown wire 1 Figure 6 13 Page 6 19 With the black probe test for continuity on each of the flat blades and then on the round pin of the AC plug on the retractable cord reel The tester ...

Page 151: ... AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 6 14 Page 6 19 4 Disconnect the short AC cord from the retractable cord reel 5 Remove the charger cover 6 Disconnect the green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 6 15 Page 6 20 Figure 6 13 AC Cord and Retractable ...

Page 152: ... is obtained the AC cord and retractable cord reel must be tested independently of each other 11 If the correct readings are obtained in all of the previous steps the short AC cord is functioning properly Proceed to the following test procedure to test the retractable cord reel Retractable Cord Reel Check continuity of the AC cord and retractable cord reel at the same time 1 Disconnect the AC cord...

Page 153: ...4 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 6 17 Page 6 24 4 Disconnect the red wire of the DC cord from the heatsink 5 Disconnect the blue wire from the control board 6 Using a multimeter set for 200 ohms place the red probe on the red wire of the DC cord Test for con tinuity on each of the wires on the oth...

Page 154: ... battery charger from the vehi cle See Onboard Charger Removal on page 6 34 2 Remove the charger cover 3 Remove the transformer tan secondary coil wire from the upper terminal of the heatsink Figure 6 12 Page 6 17 4 Remove the other transformer tan secondary coil wire from the bottom terminal of the heatsink and place the continuity test clip on the ammeter buss bar 3 Figure 6 18 Page 6 24 Test fo...

Page 155: ...o batteries Figure 6 5 Page 6 11 Use jumper wires if necessary The tester should indicate continuity on relay terminals 6 and 9 and terminals 4 and 7 If tester does not indicate continuity on both sets of contacts the relay must be replaced Ammeter 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboard Charger Removal on page 6 34 2 R...

Page 156: ...ge 6 34 2 Remove the charger cover 3 Remove the DC cord black wire 4 from the ammeter by loosening the nut 1 Support the terminal as the nut is loosened to prevent rotation of the connection Figure 6 18 Page 6 24 4 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink 5 Remove the wire tie that secures the DC cord wire to the secondary coil wire tan 6 Remove the wire tie on th...

Page 157: ... screws starting with the bottom holes Tighten the screws to 11 in lb 1 2 N m HEATSINK Heatsink Removal 1 Disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 See preceding WARNING 2 Remove the charger cover 3 Remove both secondary coil transformer wires tan from the heatsink Figure 6 12 Page 6 17 4 Remove the two red wires from the heatsi...

Page 158: ... 4 Page 6 6 3 Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in lb 2 5 N m 4 Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in lb 2 0 N m 5 Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in lb 2 0 N m 6 Con...

Page 159: ...ammeter to the charger face 5 Remove the ammeter from the face of the charger Ammeter Installation 1 Place the ammeter in position in the charger face Figure 6 19 Page 6 27 2 Install nuts 2 and tighten until ammeter is firmly secured 3 Connect the DC cord black wire 5 to the left as viewed from inside the charger post of the ammeter 4 Connect the buss bar 3 from the fuse link to the right post of ...

Page 160: ...wed from the front of the charger 2 Install the buss bar 3 over the center branch of the fuse assembly and ammeter post Figure 6 19 Page 6 27 Tighten to 22 in lb 2 5 N m 3 Install a secondary coil transformer wire black onto one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary coil transformer wire black onto the remaining ter minal Tighten to 22 in l...

Page 161: ... top AC circuit breaker and remove the circuit breaker through the mounting hole in the face of the charger 6 Repeat step 5 for the removal of the bottom circuit breaker AC Circuit Breaker Installation Install in reverse order of removal CHARGER AC CORD AND RETRACTABLE CORD REEL See General Warning Section 1 Page 1 1 Short AC Cord Removal 1 Disconnect the DC cord the AC cord from the wall outlet a...

Page 162: ... 2 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord reel by gently cutting the heatshrink tubing Figure 6 14 Page 6 19 3 Disconnect the short AC cord from the retractable cord reel 4 Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transporter 4 and 6 Remove four screws 1 securing the cord reel housing 2 and its backing plate 3 to vehicle Figure ...

Page 163: ...battery charger from the vehicle See Onboard Charger Removal on page 6 34 See WARNING on page 6 24 3 Remove the charger cover 4 To apply AC power directly to the transformer primary coil the relay must be bypassed 4 1 To bypass the relay locate the black wire that goes from the circuit breaker to terminal 9 on the relay Disconnect the black wire from the relay terminal Figure 6 22 Page 6 33 4 2 Di...

Page 164: ...rd Charger Removal on page 6 34 See WARNING on page 6 24 9 Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the relay Figure 6 22 Page 6 33 See following WARNING ý WARNING The relay wiring must be properly connected prior to placing the charger back into normal service Failure to remove the jumper wire and properly connect the relay wiring could re...

Page 165: ...RED RED RED RED BLUE BLUE BLUE BLACK BLACK BLACK AC CIRCUIT BREAKERS AC CORD CONTROL BOARD GREEN or GREEN YELLOW TAN TAN DIODES WITH HEATSINK AMMETER TRANSFORMER PRIMARY COIL SECONDARY COIL CASE GROUND BLACK or BROWN WHITE or BLUE BLACK BLACK BLACK BLACK 1 BLACK BLACK BLACK BLACK BLACK 1 TAN 1 TAN 6 TAN 1 TAN 6 TAN 5 TAN 4 TAN 3 TAN 2 BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLK BLK BLACK 6...

Page 166: ...rd reel Figure 6 14 Page 6 19 4 Remove hardware securing charger to chassis 4 1 Villager 6 and 8 Remove four bolts 2 flat washers 3 lock washers 4 and nuts 5 from charger mounting plates 4 2 Carryall 2 252 Turf 2 252 and XRT 900 Remove two bolts 2 from topside of charger mounting plate 4 3 Carryall 6 and Transporter 4 and 6 Remove two nuts 5 from underside of charger mounting plate 5 Lift charger ...

Page 167: ... Installation 2008 Export Battery Charger Maintenance and Service Manual Page 6 35 6 Figure 6 23 Onboard Charger Mounting Details TURF 2 252 CARRYALL 2 252 XRT 900 TRANSPORTER 4 TRANSPORTER 6 CARRYALL 6 To AC Cord Reel VILLAGER 6 VILLAGER 8 5 6 5 4 3 1 1 1 2 2 ...

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Page 169: ...ltage 5 34 state of charge test 5 22 battery charger operation 5 6 repairs 5 27 testing 5 9 battery condition after a charge cycle 5 8 breaker charger circuit see circuit breaker charge circuit 5 3 circuit breaker installation 5 33 removal 5 32 testing 5 27 cord charger see AC cord or DC cord DC cord installation 5 28 removal 5 27 testing 5 20 5 24 diodes charger see heatsink electrical system cha...

Page 170: ... link installation 6 28 removal 6 28 heatsink installation 6 25 removal 6 25 testing 6 14 relay installation 6 28 removal 6 28 testing 6 23 retractable AC cord reel installation 6 30 removal 6 30 testing 6 20 test procedures 1 faulty receptacle connection 6 10 1 low battery voltage 6 10 2 control board 6 12 3 AC cord continuity check 6 13 3 AC power 6 13 4 diodes 6 14 5 DC circuit continuity test ...

Page 171: ...3 21 4 diodes 3 22 5 DC circuit continuity test 3 23 6 transformer 3 24 7 battery state of charge 3 25 8 continuity AC circuit breaker 3 29 AC cord 3 26 ammeter 3 29 DC cord 3 27 relay 3 29 transformer 3 28 voltage suppressor 3 29 transformer installation 3 32 removal 3 32 testing 3 24 3 28 troubleshooting 3 14 voltage suppressor installation 3 34 removal 3 34 testing 3 29 PowerDrive charger onboa...

Page 172: ...voltage 4 11 2 control board 4 13 3 AC cord continuity check 4 15 3 AC power 4 15 4 diodes 4 16 5 DC circuit continuity test 4 18 6 transformer 4 19 7 battery state of charge 4 20 8 continuity AC circuit breaker internal 4 26 AC cord with retractable cord reel 4 21 AC cord without retractable cord reel 4 21 ammeter 4 25 DC cord 4 24 relay 4 25 retractable cord reel 4 23 transformer 4 24 transforme...

Page 173: ...larity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following catgories Your Comments Are Appreciated Please select your category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other _____...

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Page 176: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 ...