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1. Please fax a copy of this page to 706 228 2662 Thank You Club Car Technical Publication Department 2008 Export Battery Charger Maintenance and Service Manual am Ingersoll Rand Industrial Technologies Club Car Club Car Inc Web www clubcar com P O Box 204658 Phone 1 706 863 3000 Augusta GA 30917 4658 1 800 ClubCar USA Intl 1 706 863 3000 Fax 1 706 863 5808
2. 4 21 AC cord without retractable cord reel 4 21 amimelter soseen atep raient ainera oeeie Enn 4 25 DIER e Ke ERTE EA A RETT 4 24 Ky 4 25 retractable cord reel sssssssss 4 23 transformer sois iena n nie 4 24 transformer installation sesesseeseeseeen 4 28 temoVal ai nid cet et eset 4 28 testirig 5 ac eter Ebr AE 4 19 troubleshooting eeen 4 8 S specifications battery charger 2 1 suppressor voltage see voltage suppressor Page i 4 T test procedures 8 continuity AC charger receptacle sss 5 23 AC cord and AC charger receptacle 5 22 W WARNING definition of iieri eere eee 1 1 2008 Export Battery Charger Maintenance and Service Manual Your Comments Are Appreciated Please select your category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other In order to help us better serve you please rate this publication in the following catgories 1 Ease of Understanding 2 Ease of Finding Information 3 Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Comments Suggestions Poor Fair Average Good Excellent
3. 6 EXPORT IQ PLUS CHARGER ONBOARD Charger Repairs TRANSFORMER See General Warning Section 1 Page 1 1 Transformer Removal 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 See WARNING on page 6 24 2 Remove the charger cover 3 Note the locations of wire ties and remove the wire ties 4 Disconnect the black primary coil leads from the AC circuit breakers and the voltage selector switch Figure 6 20 Page 6 29 and Figure 6 22 Page 6 33 Disconnect the two tan secondary coil transformer wires from heatsink Figure 6 12 Page 6 17 Disconnect the two black secondary coil transformer wires from the fuse 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 Ib 3 2 N m Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Figure 6 4 Page 6 6 Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the other secondary coil transformer wire tan to
4. K em SUE RED WIRE A TO HEATSINK BLUE WIRE TO DC CORD Figure 4 12 Control Board Page 4 14 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures TEST PROCEDURE 3 AC POWER AND CONTINUITY CHECK OF AC CIRCUIT See General Warning Section 1 Page 1 1 1 Disconnect the AC power supply cord from the wall outlet 2 Check the AC circuit breakers on the front of the charger and reset it if necessary 3 4 With a multimeter set to 500 volts AC check incoming AC voltage Insert multimeter test probes into AC Check the AC line fuse or circuit breaker in the storage facility 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 voltage for your area have building wiring checked by a licensed electrical contractor SETTING ON AC VOLTAGE MINIMUM AC VOLTAGE MAXIMUM AC VOLTAGE SELECTOR SWITCH PERMITTED PERMITTED 100 Volts AC 95 105 200 Volts AC 190 210 220 Volts AC 209 231 240 Volts AC 228 252 5 Check continuity of the AC circuit 5 1 Remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 5 2 Remove 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
5. 6 16 6 transformer seessssssseseseeeee 6 16 7 battery state of charge sssss 6 18 8 continuity AC circuit breaker internal 6 23 AC cord with retractable cord reel 6 18 amimeter oisein ii iiidid 6 23 DG GOrd MEE E E N 6 21 relay dra e este e A aE 6 23 retractable cord reel sssussse 6 20 transformer initie a oaei 6 22 transformer installation ssessesseseeeen 6 26 removal ecd echec ere ete ne ides 6 26 testilig ciini tice a oti egeo 6 16 troubleshooting eeen 6 7 test procedures 8 continuity AC cord without retractable cord reel 6 19 PowerDrive charger external AC circuit breaker charger see circuit breaker AC cord installation ottiene 3 36 removal enti tte ima 3 36 testing uinea n ert dades 3 26 ammeter installation ned ees 3 33 remloVval re ERE 3 33 testing rrr ee ee 3 29 batteries battery condition after a charger cycle 3 14 charging batteries that have low voltage 3 37 state of charge test ssesssssess 3 25 Page i 2 2008 Export Battery Charger Maintenance and Service Manual INDEX battery charger sse 3 1 features ui on Ae eat tete tein 3 2 iristallatiOr 5 iieri reti eco ete 3 9 Operation ete e 3 11 epa S iuri HR e es 3 30 COSTING eee trem in Rr rA nem 3 12
6. If the charger works with one vehicle but does not work with another vehicle then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD SOLID STATE COMPUTER SPEED CONTROLLER fi FUSE LINK I l N 10 BLACK iia TM TL E 5t NE TERMINAL RED TO BLACK TERES POSITIVE 7 CHARGER OY TERMINAL none ARN RECEPTACLE N I 10 BLACK al 18 GRAY IN 18 GRAY 10 RED To Solenoid SENSE LEAD FUSE BLACK TO NEGATIVE TERMINAL Figure 3 3 Charge Circuit and Battery Configuration Turf 1 and Carryall 1 Page 3 4 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL The Charge Circuit EE PRECEDENT 4 X 12 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 4 Page 3 5 or Figure 3 5 Page 3 6 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the char
7. 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 switch position Check switch position for proper incoming AC voltage selection Battery warning light illuminates for ten seconds at four second intervals 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 15 Onboard computer malfunction Test Procedure 2 Control Board on page 4 13 Charger failure See Testing Charger Operation on page 4 6 16 hour time out See Battery Warning Light on page 4 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Batteries are getting close to full discharge capacity Recharge batteries as soon as possible Page 4 10 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 INDEX OF TEST PROCEDURES Battery Voltage Control Board AC Power and Continuity Check of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test ON OOK WD Continuity TEST PROCEDURE 1 BATTERY VOLTAGE See General Warning Section
8. Control Board on page 4 13 Relay closes with an audible 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 on page 4 15 Transformer primary coil Test Procedure 6 Transformer on page 4 19 Relay Test Procedure 8 Continuity on page 4 21 Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 4 Diodes on page 4 16 Both Diodes failed Test Procedure 4B Both Diodes Failed on page 4 17 Onboard computer malfunction Test Procedure 2 Control Board on page 4 13 Failed transformer or voltage switch Test Procedure 6 Transformer on page 4 19 Failed ammeter Replace ammeter Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 4 21 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 4 16 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page 2008 Export Battery Charger Maintenan
9. EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures EX CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER FUSE Figure 5 8 Receptacle Wire Connections 3 5 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sense lead fuse to the onboard computer gray wire See following WARNING A WARNING Do not bypass the sense lead fuse 3 6 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistance 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 charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 5 34 2008 Export Battery Charger Maintenance and Service Manual Page 5 15 E EXPORT IQ PLUS CHARGER EXTERNAL Place multimeter red 4 probe here TURF 2 252 VEHICLES CARRYALL 2 252 VEHICLES XRT 900 VEHICLES SS Place multimeter black probe here VILLAGER 6 AND 8 VEHICLES FRONT OF VEHICLE Place multimeter Place multimeter red probe here Pla
10. 3 Remove positive battery cable 3 Remove positive battery cable Connect battery cables in reverse order Connect battery cables in reverse order Page 1 6 2008 Export Battery Charger Maintenance and Service Manual SECTION 2 CHARGER IDENTIFICATION AND SPECIFICATIONS GENERAL INFORMATION 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 battery charger See Battery Charger Identi fication on page 2 6 BATTERY CHARGER SPECIFICATIONS EXPORT POWERDRIVE EXTERNAL CHARGER Export PowerDrive External SPECIFICATIONS Battery Charger MODEL NUMBER 18780 11 18780 18 CCI P N 101831503 101831504 AC INPUT AC voltage 100 200 220 or 240 VAC selectable AC voltage acceptable range at 100 VAC setting 95 105 95 105 AC voltage 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 6 3 Max AC current amps at 220 VAC 50 Hz 6 9 6 9 Max AC cur
11. CHARGER IDENTIFICATION AND SPECIFICATIONS Battery Charger Specifications EXPORT POWERDRIVE ONBOARD CHARGER SPECIFICATIONS Export PowerDrive Onboard Battery Charger Model number 17790 10 17790 11 17790 12 17790 40 CCI P N 101831601 101831602 101831603 102546902 17 ft 5 2 m 17 ft 5 2 m 17 ft 5 2 m 17 ft 5 2 m AC cord length retractable retractable retractable retractable 80 5 in 129 5 in 162 5 in 9 5 in DC cord length 204 5 cm 328 9 cm 412 8 cm 24 cm Weight 37 Ib 16 8 kg 37 7 Ib 17 1 kg 38 2 Ib 17 3 kg 37 Ib 16 8 kg MOUNTING CONFIGURATION Mounting Onboard secured to the vehicle 2008 Export Battery Charger Maintenance and Service Manual Page 2 3 CHARGER IDENTIFICATION AND SPECIFICATIONS Battery Charger Specifications EXPORT IQ PLUS EXTERNAL CHARGER Export IQ Plus External SPECIFICATIONS Battery Charger Model number 25880 11 25880 18 CCI P N 102892901 102892902 AC INPUT AC voltage 100 200 220 or 240 VAC selectable AC voltage acceptable range at 100 VAC setting 95 105 95 105 AC voltage acceptable range at 200 VAC setting 190 210 190 210 AC voltage acceptable range E at 220 VAC setting 209 231 209 231 AC voltage acceptable range 2 E at 240 VAC setting 228 252 228 25
12. Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock An extension cord 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 charger dry Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slowly Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not connect a stationary charger to the receptacle if the charger cord pl
13. 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 use the CDM Communication Display Module CCI P N 101831801 See Communication Display Module CDM in Section 11 of the appropriate maintenance and service supplement Figure 5 4 Charger Receptacle Figure 5 5 Incorrect Charger Cord Removal 2008 Export Battery Charger Maintenance and Service Manual Page 5 7 E EXPORT IQ PLUS CHARGER EXTERNAL Checking Battery Condition with an External Charger EXTERNAL CHARGER PLUG AND RECEPTACLE When inserting the DC plug into the vehicle receptacle align the raised guide on the plug with the guide slot in the receptacle and slowly push the plug straight in Figure 5 4 Page 5 7 To disconnect the plug from the vehicle firmly grasp the plug not the cord Figure 5 5 Page 5 7 and slowly pull plug straight out See fol lowing WARNING and CAUTION A WARNING 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 5 4 The battery charger DC plug must be pulled slowly from the receptacle Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Do not use a battery charger if the cord plug or receptacle is
14. See General Warning Section 1 Page 1 1 The battery charger DC plug must be pulled slowly from the receptacle Figure 3 8 Page 3 10 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 3 9 Page 3 10 GENERAL INFORMATION This section includes information pertaining to service of the Export PowerDrive battery charger model num bers 18780 11 and 18780 18 Depending on the geographic region the charger provided with your vehicle may be a different model Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor The PowerDrive battery charger is automatic and has no external controls Figure 3 1 Page 3 1 When the charger is connected there is a 2 to 15 second delay before charging begins See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer OBC records the amount of energy consumed as the vehicle is used then directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger shuts off automatically preventing the possibility of either undercharging o
15. test Disconnect one transformer secondary coil wire from the diode terminal Figure 5 11 Page 5 19 probe to the diode mounting plate and the black test probe to a diode terminal and note the reading Figure 5 11 Page 5 19 Page 5 18 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures EX 5 Reverse test probes and check each diode again and note the reading Figure 5 12 Page 5 19 A diode is designed to conduct current in one direction only If a diode conducts current shows continuity in both directions the entire heatsink with diodes must be replaced If a diode does not conduct current does not show continuity in either direction the entire heatsink must be replaced 6 On rare occasions a single fuse link may blow due to excessive heat This can be caused by a loose internal fuse connection Check all three fuse connections inside the charger to be sure they are clean and tight The proper tightness for the fuse link connections is 22 in Ib 2 5 N m 7 Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION f connections are not clean and tight excessive heat will be created and the charger may become damaged Disconnect secondary coil lead Figure 5 11 Diode Test Figure 5 12 Diode Test Probes Reversed Test Procedure 4B Both Diodes Failed S
16. A 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 batteries fully charged disconnect the AC charger plug for approximately 20 seconds and reconnect it The ammeter should jump to a reading between 14 and 18 amps and taper to below 5 amps within 15 minutes 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Control Board on page 4 13 See following NOTE NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Batteries section in the appropriate maintenance and service manual Page 4 20 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 Short AC Cord and Retractable Cord Reel Check continuity of the short AC cord and retractable 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 charge
17. Both diodes failed Test Procedure 4B Both Diodes Failed on page 3 23 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 21 Failed transformer or voltage switch Test Procedure 6 Transformer on page 3 24 Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 3 26 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 3 22 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page 2008 Export Battery Charger Maintenance and Service Manual Page 3 15 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Troubleshooting EXPORT POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B Both Diodes Failed on page 3 23 Charger output is low One diode failed Test Procedure 4A Single Diode Failure on page 3 22 Transformer coil short circuit failure Test Procedure 6 Transformer on page 3 24 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 21 Charger turns off too soon AC power s
18. CIRCUIT SURGE e BREAKER oo a CURRENT LIMITER Figure 5 22 Export IQ Plus Charger Wiring Diagram Relay Bypassed A 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 9 Install the charger cover and the retaining screws 10 Plug the 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 determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual 2008 Export Battery Charger Maintenance and Service Manual Page 5 35 SECTION 6 EXPORT IQ PLUS CHARGER ONBOARD A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 GENERAL INFORMATION This section includes information pertaining to service of the Export onboard IQ Plus battery charger model number 25660 40 as installed in IQ Plus vehicles Depending on the
19. Figure 5 6 Page 5 9 and Figure 5 7 Page 5 13 Disconnect the two tan secondary coil transformer wires from heatsink Disconnect the two black secondary coil transformer wires from the fuse Remove the four bolts and nuts that mount the transformer to the case and remove the transformer Transformer Installation 1 10 Install the transformer with the secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in Ib 3 2 N m Figure 5 7 Page 5 13 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the black primary coil transformer wire marked 6 to the bottom terminal of the top AC circuit breaker Connect the black primary coil transformer wire marked 1 to the bottom terminal of the bottom AC circuit breaker Connect each of the remaining black primary coil transformer wires marked 2 3 4 and 5 to the corre sponding terminals marked on the voltage selector switch Set the voltage selector switch to the appropriate voltage matching the
20. If any other reading is obtained the DC cord must be replaced Transformer The PowerDrive battery charger transformer has two sets of coils a primary coil and a secondary coil Figure 4 27 Page 4 34 Primary Coil 1 Ou ros T 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 4 35 Remove the charger cover Disconnect the black wires marked 1 and 6 from the AC circuit breakers Disconnect the wires marked 2 3 4 and 5 from the voltage selector switch Place the continuity tester probes on the primary coil transformer wires disconnected above in pairs until all of the combinations in the following chart have been tested If the continuity readings agree with the chart replace the voltage selector switch If the continuity read ings differ from the chart replace the transformer Secondary Coil 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 4 35 2 Remove the charger cover 3 Remove the transformer tan secondary coil wire from the upper terminal of the heatsink Figure 4 5 Page 4 7 Page 4 24 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures PRIMARY COIL CONTINUITY NO CONTINUITY CHART NEGATIVE PROBE 1 2 3 4 5
21. Page 5 9 The tester should indicate continuity on the ground pin only If any 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 charger receptacle or connecting wires have failed and must be replaced 200 OHM SETTING NN S AC CIRCUIT AC CHARGER RECEPTACLE Figure 5 18 AC Charger Receptacle Continuity Test DC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 To check the continuity of the DC cord disconnect the black wire 17 of the DC cord from the ammeter Figure 5 19 Page 5 25 4 Disconnect the red wire 19 of the DC cord from the heatsink 5 Disconnect the blue wire 18 from the limiter 15 which connects to the red wire assembly that connects to the charger relay Page 5 24 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures EX 6 Place the clip of the continuity tester on the red wire 19 of the DC cord 7 Place the continuity test probe on the positive pin of the DC plug positive and negative pins
22. Page 6 35 3 For Carryall 2 252 and 6 Turf 2 252 XRT 900 and Transporter 4 and 6 vehicles Carefully remove the heatshrink tubing from the AC cord connection and disconnect the short AC cord from the retractable cord 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 assembly from vehicle Onboard Charger Installation 1 Installation is reverse of removal 2 Install and tighten hardware securing charger to chassis 2 1 Villager 6 and 8 Tighten four bolts 2 and nuts 5 to 108 in Ib 12 N m 2 2 Carryall 2 252 Turf 2 252 and XRT 900 Tighten two bolts 2 to 108 in Ib 12 N m 2 3 Carryall 6 and Transporter 4 and 6 Tighten two nuts 5 to 108 in Ib 12 N m 3 For Carryall 2 252 and 6 Turf 2 252 XRT 900 and Transporter 4 and 6 vehicles Place new heat shrink tubing 6 CCI P N 1017189 over the short AC cord and connect the short AC cord to the retract able cord reel Figure 6 23 Page 6 35 Slide the tubing over the connection and carefully apply heat to shrink it 4 Connect battery cables positive cable first and tighten to 110 in Ib 12 4
23. The tester should indicate continuity on both secondary coil wires If tester does not indicate continuity on both secondary coil wires replace transformer Ensure that the fuse is intact and not blown Voltage Suppressor Failed Closed 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Using a multimeter set to the diode test function place the black probe of the multimeter on the sense 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 cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove the black wire from terminal 6 of the relay and black wire from terminal 8 of the relay Figure 5 6 Page 5 9 Place continuity tester leads on terminals 6 and 8 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 Page 5 26 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Charger Repairs E 4 Remove the black w
24. and blue wires Figure 4 5 Page 4 7 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 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 An AC circuit test should be done before performing this test procedure to ensure the continuity of the AC cord AC cord reel internal AC circuit breakers and charger wiring See Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 15 1 Disconnect 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 charger cover 4 Disconnect transformer secondary coil wires from the heatsink Figure 4 18 Page 4 20 5 To apply AC power directly to the transformer primary coil bypass the relay See Charging a Battery Pack that has Low Voltage on page 4 33 See following DANGER A 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 6 Make sure that the voltage selector switch
25. battery warning light ce 3 2 charge circuit sseessssssseeeeeee 3 3 charge interlock sees 3 2 circuit breaker installation acere 3 35 removal sects creer 3 35 testing Sees tev ee poete io teet t eid des 3 29 cord charger see AC cord or DC cord DC cord inspection ioiii 3 12 installation ssssssseeeeennnnee 3 30 KM CINE ETT 3 30 testing coo eere otc Reus 3 23 3 27 electrical system charge circuit iret recie ree 3 3 fuse link Taere oI aaee E EEEE 3 34 removal 5 i ni Ht e a 3 34 heatsink installation 5 coti eine 3 31 removal etel 3 31 testing e erem RAE net 3 22 long term storage charge 3 2 onboard computer testing oie e eerte os 3 21 relay installation erret 3 35 removal x 2 dti tere greed pendeat 3 35 testing jose Aad deat en eR ADM 3 29 solenoid lockout c ccccceeeceeeeeeeeetteeeeeeees 3 2 test procedures 1 battery voltage uieii 3 18 1 DC plug and receptacle 3 18 2 onboard computer eesseeesess 3 21 3 AC power and continuity test 3 21 A diodes eitis del 3 22 5 DC circuit continuity test 3 23 6 transformer ssssseeeee 3 24 7 battery state of charge oo eects 3 25 2008 Export Battery Charger Maintenance and Service
26. use the CDM Communication Display Module CCI P N 101831801 See Communication Display Module CDM in Section 11 of the appropriate maintenance and service manual TESTING CHARGER OPERATION 1 With the DC plug disconnected from the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 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 3 rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 3 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 3 2 Page 3 3 through Figure 3 7 Page 3 8 and that the internal charger wiring is correct Figure 3 11 Page 3 13 DC CORD AND PLUG INSPECTION The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug
27. 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 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 6 5 Page 6 11 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 34 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 6 31 Page 6 10 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Place multimeter black probe here Place multimeter red probe here VILLAGER 6 AND 8 VEHICLES FRONT OF VEHICLE Place multimeter black probe here OF VEHICLE Test Procedures 6 Place multimeter red probe here TURF 2 252 VEHICLES CARRYALL 2 252 VEHICLES XRT 900 VEHICLES Place multimeter black probe here Place multimeter red probe here Figure 6 5 Battery Configurations 2008 Export Battery Charger Maintenance and Service Manual Page 6 11 E EXPORT IQ PLUS CHARGER ONBOARD Test Procedures TEST PROC
28. 1 1 Fuse Link Removal 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 4 35 See WARNING on page 4 26 2 Remove the charger cover 3 Remove both black secondary coil transformer wires and the buss bar 3 from the back of the fuse link assembly Figure 4 25 Page 4 29 4 Remove screws from the front of the charger and remove the fuse 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 Ib 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 Ib 2 5 N m 4 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 36 5 Check charger for proper operation CHARGER RELAY See General Warning Section 1 Page 1 1 Charger Relay Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboar
29. 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 17 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 17 Charger failure See Testing Charger Operation on page 5 9 16 hour time out See Battery Warning Light on page 5 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Battery warning light illuminates for ten seconds at four second intervals with DC charger cord disconnected 25 seconds at 10 second intervals for Precedent vehicles Batteries are getting close to full discharge capacity Recharge batteries Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 17 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Page 5 12 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Troubleshooting EX Figure 5 7 IQ Plus Battery Charger Export Exploded View 2008 Export Battery Charger Maintenance and Service Manual Page 5 13 a EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 INDEX OF TEST PROCEDURES Battery Voltage and D
30. 6 Checking Battery Condition with an Onboard Charger ssssss ee 6 7 Start Charge Gycle e tuae e dedu ette ona 6 7 Troubleshooting 2 tiri hetero theo E EAEE eed ba hat dg cu dude 6 7 WTest Procedures 2 ise cie ee ote e eaae i ood sons EEE EE TEE E dccatedl BED D ere Biel D ELE 6 10 Indexcof Test ProCedures i5 getreten oe a Lebe 6 10 Charger RONAN nieren teh e t tea D E d md 6 24 DC Conds ee on mna dom 6 24 Ia rich gem 6 25 Jransformel 3 2 eden Pes deed eode ede de e E DU e D Nx E CO E EET Lee ra Ee IRE 6 26 AMME Re MM LLLI 6 27 EuseDink 3 ense eoe m Id auiem 6 28 Charger Relay tenen go pe etie eigen la pe ep epe quie eite eda E Eee ipd 6 28 Charger AC Circutt Breaker io d e cena Ue AA 6 29 Charger AC Cord and Retractable Cord Reel ssssssssssseee ener 6 29 Charging a Battery Pack that has Low Voltage essem emen 6 31 Onboard Charger Removal and Installation seeeen eme 6 34 SECTION i INDEX Page vi 2008 Export Battery Charger Maintenance and Service Manual 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
31. 6 P F No No No Conunulty EORUnuty Continuity Continuity Continuity ee v No No No w Continuity Continuity Continuity Continuity Continuity O No No No PER M n Continuity Continuity Continuity Continuity Coan wi 2 No No No ae m 5 Continuity Continuity Continuity Continuity Continuity o a No No No TE A Continuity Continuity Continuity Continuity Continuity No No No Ar Continuity Continuity Continuity Continuity Continuity 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 4 24 Page 4 27 Test for continuity between the buss bar and each of the secondary coil wires tan The tester should indicate continuity between the buss bar and both of the secondary coil wires If tester does not indicate continuity on both secondary coil wires replace transformer Ensure that the fuse is intact and not blown Relay 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 4 35 2 Remove the charger cover 3 Remove the black wire from terminal 6 of the relay and black wire from terminal 9 of the relay Figure 4 26 Page 4 31 Place continuity tester leads on terminals 6 and 9 of the relay The tester should indicate no continuity If tester indicates continuity the relay contacts have failed close
32. 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 Blown charger fuse Test Procedure 4 Diodes on page 6 14 ammeter does not move Both Diodes failed Test Procedure 4B Both Diodes Failed on page 6 15 Onboard computer malfunction Test Procedure 2 Control Board on page 6 12 Failed transformer Test Procedure 6 Transformer on page 6 16 Failed ammeter Replace ammeter Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 6 18 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 6 14 Loose internal fuse connection Tighten connection Both charger fuse links blow or Battery is wired in reverse polarity Check vehicle wiring receptacle fuse link blows DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B Both Diodes Failed on page 6 15 Troubleshooting Guide continued on next page Page 6 8 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ P
33. Circuit on page 5 17 Transformer primary coil Test Procedure 6 Transformer on page 5 20 Relay Test Procedure 8 Continuity on page 5 22 Failed ammeter Replace ammeter Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 5 Charger DC Circuit Continuity Test on page 5 20 Both diodes failed Test Procedure 4B Both Diodes Failed on page 5 19 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 17 Failed transformer or voltage switch Test Procedure 6 Transformer on page 5 20 Relay operates intermittently Failed charger relay Test Procedure 8 Continuity on page 5 22 Single charger fuse link blows Diode failed Test Procedure 4A Single Diode Failure on page 5 18 Loose internal fuse connection Tighten connection Troubleshooting Guide continued on next page 2008 Export Battery Charger Maintenance and Service Manual Page 5 11 ESI EXPORT IQ PLUS CHARGER EXTERNAL Troubleshooting EXPORT IQ PLUS BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B Both Diodes
34. DC cord DC cord installation 4 26 removal x teste bse hse eet ere Rerum 4 26 TESTING x time Illes 4 18 4 24 INDEX diodes charger see heatsink electrical system Charge Cmrcult sedare a pH 4 2 fuse link installation sesesseesseseeee 4 30 temmoVal z e ern tatis 4 30 heatsink installation nce 4 27 removal sonn ener eee 4 27 testing nee pee 4 16 long term storage charge 4 2 relay installation eeeessessseseen 4 31 removal sv S xt UL 4 30 testing nsec eek Oh Artes beoe EE 4 25 retractable AC cord reel installation eesesssesseseeen 4 32 removal 3 eret e Ren Re Enni 4 32 POSTING iet ERR UEM IRRENRRE 4 23 solenoid lockout sseeees 4 2 test procedures 1 faulty receptacle connection 4 11 1 low battery voltage sessssss 4 11 2 control board sseesesseseeeeeeee 4 13 3 AC cord continuity check 4 15 3 AC POWER ooo ceecccee eee ceeteeeteeceedeeeteeseeteesteners 4 15 A diodes ere REDE 4 16 5 DC circuit continuity test 4 18 6 transformer esses 4 19 7 battery state of charge ssssss 4 20 8 continuity AC circuit breaker internal 4 26 AC cord with retractable cord reel
35. DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 Use the following Troubleshooting Guide for troubleshooting export PowerDrive onboard battery chargers model numbers 17790 10 and 17790 40 The Troubleshooting Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages Page 4 8 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Troubleshooting EXPORT POWERDRIVE ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected Connect batteries See Figure 4 6 Page 4 12 through Figure 4 9 Page 4 13 Battery voltage is too low Test Procedure 1 Battery Voltage on page 4 11 Improper vehicle or battery charger wiring See Figure 4 2 Page 4 3 Figure 4 3 Page 4 3 Figure 4 5 Page 4 7 Figure 4 6 Page 4 12 Figure 4 7 Page 4 12 Figure 4 8 Page 4 12 and Figure 4 9 Page 4 13 DC circuit Test Procedure 5 Charger DC Circuit Continuity Test on page 4 18 Onboard computer malfunction Test Procedure 2 Control Board on page 4 13 Gray sense lead fuse is blown Test Procedure 1 Battery Voltage on page 4 11 Control board malfunction Test Procedure 2
36. 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 Ib 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 the charger protects the onboard com puter by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehicle See Test Procedure 8 Continuity on page 3 26 Voltage Suppressor Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 3 30 Remove the charger cover Remove nut attaching voltage suppressor 18 gauge red wire to heatsink Boo Disconnect blue wire to DC cord at quick disconnect terminal 5 Disconnect the voltage suppressor wire assembly from charger relay Voltage Suppressor Installation Install in reverse order of removal Tighten nut attaching voltage suppressor 18 gauge red wire to heatsink to 18 in Ib 2 0 N m Page 3 34 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Repairs 3 CHARGER RELAY See General Warning Section 1
37. ONBOARD CHARGER FEATURES Charge Interlock When the AC power cord is inserted into a wall receptacle the onboard computer locks out the vehicle s drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge PowerDrive chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically acti vate the charger every 15 days To return the vehicle to service disconnect the AC cord from the wall outlet wait 15 seconds and then plug the AC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before putting it into service BATTERY WARNING LIGHT The 48 volt electric vehicle features a dash mounted battery warning light that alerts the operator to any prob lems with the batteries or charging system The battery warning light is controlled by the onboard computer OBC When the batteries receive an incomplete charge because 1 AC power to charger is interrupted 2 automatic charger shut off occurs after 16 hours of operation or 3 charger malfunctions the battery warning light will indicate as follows The battery warning light will not illuminate if the charge is 90 or more complete The onboard com puter will retain in memory the amount of charge needed to fully replenish the batteries and will com p
38. SELECTION SWITCH REAR CHARGER PANEL Figure 4 4 AC Input Voltage Selection Switch Connect the power supply cord to an AC supply within the acceptable voltage range See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with all applica ble national and local electrical codes and regulations Place the charger AC cord so it will not be stepped on tripped over or otherwise subject to damage or stress The use of an extension cord with the onboard charger should be avoided Do not place items in the compartment where the battery charger is installed Ensure that the charger venti lation slots are unobstructed NORMAL CHARGER OPERATION 1 Connect the AC power supply cord into an AC outlet designed to provide the proper AC voltage for the charger 2 The charger will activate automatically within 2 to 15 seconds 2008 Export Battery Charger Maintenance and Service Manual Page 4 5 EXPORT POWERDRIVE CHARGER ONBOARD Charger Operation 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in
39. Short AC Cord Test 7 Disconnect the black wire 1 of AC cord from the control board 8 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 10 11 1 Test for continuity on each of the flat blades and then 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 short AC cord must be replaced Place the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug The tester should indicate continuity on only the round pin If any other reading is obtained the AC cord and retractable cord reel must be tested inde pendently of each other Disconnect the AC cord white wire 4 from the control board Place the red probe on the white wire 4 and check for continuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord and retractable cord reel must be tested independently of each other 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 from the w
40. Style A Figure 3 18 Battery Voltage Test Precedent Style B Battery Configuration Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 RED probe to battery no 1 1 RED probe to battery no 1 2 BLACK probe to battery no 4 2 BLACK probe to battery no 4 4 4 Style C 6 x 8 Volt Precedent 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 6 Figure 3 19 Page 3 20 Figure 3 19 Battery Voltage Test Precedent Style C Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 5 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 charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 3 37 Page 3 20 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL TEST PROCEDURE 2 ONBOARD COMPUTER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 1 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC co
41. 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 2008 Export Battery Charger Maintenance and Service Manual Page 6 17 ES EXPORT IQ PLUS CHARGER ONBOARD Test Procedures TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 1 With the batteries fully charged disconnect the AC charger plug for approximately 20 seconds and reconnect it The ammeter should jump to a reading between 14 and 18 amps and taper to below 5 amps within 15 minutes If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Control Board on page 6 12 See following NOTE NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Batteries section in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 Short AC Cord and Retractable Cord Reel Check continuity of the short AC cord and retractable cord reel at the same time 1 e Disconnect the AC cord from the wall outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 3 4 Disconnect the green o
42. Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on 6 page 4 36 Check charger for proper operation Retractable AC Cord Reel Removal 1 Disconnect retractable AC cord from AC outlet See Onboard Charger Removal on page 4 35 See WARNING on page 4 26 2 Remove the charger cover 3 Remove the heatshrink from the AC cord connection between the short AC cord and the retractable cord 4 reel by gently cutting the heatshrink tubing Figure 4 20 Page 4 22 Disconnect the short AC cord from the retractable cord reel Retractable AC Cord Reel Installation Install in reverse order of removal Page 4 32 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 5 Page 4 7 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 If battery pack voltage is below 34 volts the charger will not activate The char
43. and begin charging 7 Allow to charge for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 8 After one or two hours disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 See WARNING on page 4 26 9 Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the relay Figure 4 27 Page 4 34 See following WARNING 2008 Export Battery Charger Maintenance and Service Manual Page 4 33 EXPORT POWERDRIVE CHARGER ONBOARD Charging a Battery Pack that has Low Voltage A WARNING 10 11 12 13 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 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 36 Plug the AC cord into an electrical outlet Allow the charger to continue charging the batteries until the charger shuts off automatically 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 electr
44. and receptacle and could cause batteries to explode BATTERY WARNING LIGHT The 48 volt electric vehicle 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 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 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 DC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 9096 complete but the vehicle has enough power for 30 minutes of operation This will alert the fleet operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicate
45. begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire After one or two hours disconnect the AC cord and remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 See WARNING on page 6 24 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 A WARNING 10 11 12 13 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 Install charger cover and install charger in vehicle See Onboard Charger Installation on page 6 34 Plug the AC cord into an electrical outlet Allow the charger to continue charging the batteries until the charger shuts off automatically 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 determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service m
46. charger dry Do not expose to rain Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other materials to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes 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 Page 4 4 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Charger Operation tions 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 4 4 Page 4 5 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 with your charger has the proper AC plug for your location If it does not contact your Club Car representative to obtain the proper cord or plug AC INPUT VOLTAGE
47. circuit consists of the following components charger receptacle receptacle fuse link onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 4 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 8 The positive terminal of the charger receptacle is connected to the positive post of battery no 1 depending on the specific vehicle model this connection to positive 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 charge circuit Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer Also check connections of the fuse link located on the charger receptacle Figure 5 2 Page 5 3 ONBOARD lt SOLID STATE COMPUTER FUSE LINK 444 SPEED CONTROLLER 10 BLACK T B J mBak M CHARGER 10 BLACK f Ss RECEPTACLE Carryall 6 Tr
48. incoming AC electrical service that will be used to power the charger Tie the wires together as they were before the wire tie was removed See following WARNING 2008 Export Battery Charger Maintenance and Service Manual Page 5 29 Charger Repairs ES IE EXPORT IQ PLUS CHARGER EXTERNAL Charger Repairs A WARNING 11 Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Install the charger cover and check charger for proper operation AMMETER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Ammeter 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 Using two wrenches to prevent the posts from turning disconnect the two black wires from the ammeter 17 Figure 5 20 Page 5 30 Remove the two nuts 22 that secure the ammeter to the charger face 5 Remove the ammeter from the face of the charger Figure 5 20 Ammeter Ammeter Installation FON Place the ammeter in position in the charger face Figure 5 20 Page 5 30 Install the nuts 22 and tighten until ammeter is firmly secured Connect the two black wires to the ammeter posts Thread nuts onto both posts of the ammeter until just past finger tight While holding the inside nut tighten the outs
49. 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 A DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death A 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 A 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 s
50. or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts Page 8 12 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Installation and Operation E 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 See Charger Receptacle in Section 12 of the appropriate maintenance and service manual for receptacle removal and installation See also DC Cord 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 DC CORDSET DIODES WITH HEATSINK a 3 BLACK FUSE AMMETER SECONDARY COIL PRIMARY COIL TRANSFORMER BLUE GRN YEL c VOLTAGE SUPPRESSOR CASE GROUND BLACK M BLACK 1 BLACK 1 BLACK 1 AC CIRCUIT BREAKERS B BLACK BLACK 4 TAN 6 TERMINAL BLACK 6 AC VOLTAGE SELECTOR SWITCH Figure 3 11 PowerDrive Export Charger Wiring Diagram 2008 Export Battery Charger Maintenance and Service Manual Page 3 13 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Checking Battery Condition After a Charge Cycle CHECKING BATTERY CONDITION AFTER A CHARGE CYCLE See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 It is commo
51. reading is normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuity of the DC circuit See Test Procedure 5 Charger DC Circuit Continuity Test on page 5 20 11 When troubleshooting and repairs are complete remove jumper wire and properly connect relay wiring See following WARNING A 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 2008 Export Battery Charger Maintenance and Service Manual Page 5 21 a EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures TEST PROCEDURE 7 BATTERY STATE OF CHARGE TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and reconnect it The ammeter should jump to a reading between 14 and 18 amps and taper to below 5 amps within 15 minutes If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Onboard Computer on page 5 17 See following NOTE NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Batteries section
52. terminal 4 4 6 Use a jumper wire with alligator clips to connect the black wire from relay terminal 7 to the blue wire from relay terminal 4 Figure 3 11 Page 3 13 See following DANGER A 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 5 Plug the DC cord into the charger receptacle first then plug the AC cord into an electrical outlet 6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 7 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 8 Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the relay Figure 3 31 Page 3 38 See following WARNING 2008 Export Battery Charger Maintenance and Service Manual Page 3 37 ES EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage A 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 prop
53. tester should indicate continuity on only the round pin If any other reading is obtained the retractable cord reel must be replaced If the correct readings are obtained in all of the previous steps the retractable cord reel is functioning properly DC Cord 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 4 35 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 4 23 Page 4 27 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 other end of the DC cord The tester should indicate continuity on the red DC cord wire only If any other reading is obtained the DC cord must be replaced Place the red probe on the blue 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 blue DC cord wire only If any other reading is obtained the DC cord must be replaced 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
54. the charger Figure 4 21 Page 4 22 2008 Export Battery Charger Maintenance and Service Manual Page 4 21 EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures Figure 4 20 Heatshrink Removal Figure 4 21 Short AC Cord Test Page 4 22 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures 8 Place the red probe on the end of the green or green yellow wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug The tester should indicate continuity on only the round pin If any other reading is obtained the AC cord and retractable cord reel must be tested independently of each other 9 Disconnect the AC cord white or blue wire 4 from the control board 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 The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord and retractable cord reel must be tested independently of each other 10 Ifthe 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 from the wall outlet
55. to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 5 4 Page 5 7 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 Monitor the ammeter Under normal operating conditions when the charger is on and the batteries are discharged the charger will shut off in order to run a self diagnostic 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 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 between charges until the bat teries have been properly seasoned 20 to 50 charge cycles
56. top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 6 Connectthe black primary coil transformer wire marked 1 to the top terminal of the top AC circuit breaker 7 Connect the black primary coil transformer wire marked 6 to the top terminal of the bottom AC circuit 10 breaker Connect each of the remaining black primary coil transformer wires marked 2 3 4 and 5 to the corre sponding terminals marked on the voltage selector switch Set the voltage selector switch to the appropriate voltage matching the incoming AC electrical service that will be used to power the charger Tie the wires together as they were before the wire tie was removed See following WARNING Page 4 28 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Charger Repairs A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 11 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 36 12 Check charger for proper operation AMMETER See General Warning Section 1 Page 1 1 Ammeter Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remove the batt
57. wall outlet and remove the 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 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 for continuity between the buss bar and each of the secondary coil wires tan The tester should indicate continuity between the buss bar and both of the secondary coil wires If tester does not indicate continuity on both secondary coil wires replace transformer Ensure that the fuse is intact and not blown Page 6 22 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Test Procedures 6 Relay 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 Remove the charger cover 3 Remove the black wire from terminal 6 of the relay and black wire from terminal 9 of the relay Figure 6 20 Page 6 29 Place continuity tester leads on terminals 6 and 9 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 4 Remove the black wire from terminal 4 of the relay
58. 1 Page 1 1 Test Procedure 1A DS Villager 4 1 Check the wire connections between the vehicle and battery charger Figure 4 2 Page 4 3 1 1 Verify that the 10 gauge red wire of the charger is connected to the positive post of battery no 1 1 2 Verify the connection of the 10 gauge black wire from the onboard computer and the 10 gauge black 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 A 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 200 ohms The resistance should be less than 2 ohms 2 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 6 Page 4 12 Normal no load voltage should be between 50 and 52 volts for fully charged batteries The voltage of the battery pack must be over 34 volts DC to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 4 33 2008 Export Battery Charger Maintenance and Service Manual Page 4 11 EXPORT POWER
59. 2 Frequency 50 Hz 60 Hz POWER CONSUMPTION Max AC current amps at 100 VAC 50 Hz 16 9 16 0 Max AC current amps at 100 VAC 60 Hz vee RS Max AC current amps at 200 VAC 50 Hz KS i Max AC current amps at 200 VAC 60 Hz TA As Max AC current amps at 220 VAC 50 Hz 70 59 Max AC current amps at 220 VAC 60 Hz d d Max AC current amps at 240 VAC 50 Hz on 64 Max AC current amps 64 64 at 240 VAC 60 Hz DC OUTPUT DC voltage VDC start of charge cycle 48 48 DC current amps start of charge cycle 17 17 DC voltage VDC end of charge cycle 60 60 DC current amps end of charge cycle 4 7 4 7 DIMENSIONS WEIGHT 10 25 in 10 25 in Case overall length 26 cm 26 cm 8 687 in 8 687 in Case overall width 22 1 cm 22 1 cm 9 0 in 9 0 in Case overall height 22 9 cm 22 9 cm AC cord length N A N A 103 in 144 in DC cord length 261 6 cm 365 8 cm r 34 8 Ib 35 3 Ib Weight 15 8 kg 16 0 kg MOUNTING CONFIGURATION Mounting Set on shelf wall mount with keyhole or hang securely from ceiling Page 2 4 2008 Export Battery Charger Maintenance and Service Manual CHARGER IDENTIFICATION AND SPECIFICATIONS Battery Charger Specifications Export IQ Plus EXPORT IQ PLUS ONBOARD CHARGER SPECIFICATIONS Onboard Battery Charger Model number 25660
60. 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 Using a multimeter set for 200 ohms place the red probe in one of the flat blade openings of the cord reel receptacle 1 Figure 4 22 Page 4 23 Test for continuity at the cord reel AC plug 2 on each of the flat blades and then 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 cord reel must be replaced 6 Place the red probe into the other flat blade opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then 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 cord reel must be replaced 200 OHM SETTING Figure 4 22 Retractable Cord Reel Test 2008 Export Battery Charger Maintenance and Service Manual Page 4 23 EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures T Place the red probe into the top center opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then on the round pin of the AC plug The
61. 31602 101831603 102546902 AC INPUT AC voltage 100 200 220 or 240 VAC selectable AC voltage acceptable range at 100 VAC setting 95 105 95 105 95 105 95 105 AC voltage acceptable range at 200 VAC setting 190 210 190 210 190 210 190 210 AC voltage acceptable range at 220 VAC setting 209 231 209 231 209 231 209 231 AC voltage acceptable range at 240 VAC setting 228 252 228 252 228 252 228 252 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 current amps at 240 VAC 50 Hz 5 9 5 9 5 9 5 9 Max AC current amps at 240 VAC 60 Hz 5 1 5 1 5 1 5 1 DC OUTPUT DC voltage VDC start of charge cycle 48 48 48 48 DC current amps start of charge cycle 17 17 17 17 DC voltage VDC end of charge cycle 60 60 60 60 DC current amps end of charge cycle 3 5 3 5 3 5 3 5 DIMENSIONS WEIGHT Case overall length way ms Ges GS aes overall width Q2 em Q2 1 cm 2d eni Q2 a en Case overall height A Ao em ees prd Specifications continued on next page Page 2 2 2008 Export Battery Charger Maintenance and Service Manual
62. 4 13 Page 4 16 6 Ifthe 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 If the charger is wired correctly check the continuity of the AC cord AC cord reel transformer primary coil and the internal AC circuit breaker individually See Test Procedure 8 Continuity on page 4 21 8 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 2008 Export Battery Charger Maintenance and Service Manual Page 4 15 EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures AC plug may have different appearance depending on geographic region Figure 4 13 AC Circuit Continuity Test TEST PROCEDURE 4 DIODES Use Test Procedure 4A Single Diode Failure on page 4 16 for single diode failures and testing of individual diodes If both diodes have failed use Test Procedure 4B Both Diodes Failed on page 4 17 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 1 A single diode failure is indicated by the failure of one fuse link closed circuit diode or by the
63. 40 CCI P N 102893001 AC INPUT AC voltage 100 200 220 or 240 VAC t selectable AC voltage acceptable range i at 100 VAC setting 95 105 AC voltage acceptable range g at 200 VAC setting 190 210 AC voltage acceptable range at 220 VAC setting 209 231 AC voltage acceptable range E at 240 VAC setting 228 252 Frequency 50 Hz 60 Hz POWER CONSUMPTION Max AC current amps 16 0 at 100 VAC 50 Hz i Max AC current amps 14 6 at 100 VAC 60 Hz Max AC current amps 76 at 200 VAC 50 Hz f Max AC current amps 74 at 200 VAC 60 Hz f Max AC current amps 70 at 220 VAC 50 Hz Max AC current amps 6 7 at 220 VAC 60 Hz Max AC current amps 6 4 at 240 VAC 50 Hz d Max AC current amps 6 1 at 240 VAC 60 Hz i DC OUTPUT DC voltage VDC start of charge cycle 48 DC current amps start of charge cycle 17 DC voltage VDC end of charge cycle 60 DC current amps end of charge cycle 4 7 DIMENSIONS WEIGHT Case overall length 28 9 om Case overall width 84 on Case overall height Qi Tes 17 ft 5 2 m AC cord length retractable DC cord length 54 2 oe X 37 0 Ib Weight 16 8 kg MOUNTING CONFIGURATION Mounting Onboard secured to the vehicle 2008 Export Battery Charger Maintenance and Service Manual Page 2 5 NN CHARGER IDENTIFICATION AND SPECIFICATIONS Battery Charger Identification BATTERY CHARGER IDENTIFICATION The battery charger can be identified by the mo
64. AC plug from the wall outlet 2 Wait 20 seconds then reconnect the AC cord to the wall outlet 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 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 will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle continues If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 6 4 Page 6 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 Use the following Troubleshooting Guide for troub
65. ACK or BROWN GREEN or GREEN YELLOW CASE GROUND BLACK AC CIRCUIT BREAKERS BLACK 6 Charger Operation DIODES WITH HEATSINK SECONDARY COIL __ PRIMARY COIL F dc JAY t PS cuse AMMETER TRANSFORMER BLACK 1 TERMINAL BLACK 4 TAN 6 BLACK AC VOLTAGE SELECTOR SWITCH Figure 4 5 Export PowerDrive Onboard Battery Charger Wiring Diagram 2008 Export Battery Charger Maintenance and Service Manual Page 4 7 EXPORT POWERDRIVE CHARGER ONBOARD Checking Battery Condition CHECKING BATTERY CONDITION See General Warning Section 1 Page 1 1 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With the PowerDrive battery charger this practice is not necessary The onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the cen ter dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart See Trouble shooting on page 4 9 If the specified test procedures identify no problems plug the AC cord into a wall out let and let it charge until the charger shuts off automatically If a problem is found correct it and charge the vehicle Normal
66. AND DC PLUG AND RECEPTACLE See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 1 Check the DC plug and the vehicle charger receptacle for damage dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspectthe 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 Figure 3 2 Page 3 3 Figure 3 3 Page 3 4 and Figure 3 7 Page 3 8 3 2 Make sure the two nuts that secure the two 10 gauge black wires to the receptacle fuse assembly are tight Figure 3 13 Page 3 18 CHARGER RECEPTACLE GRAY WIRE FROM COMPUTER SENSE LEAD FUSE Figure 3 13 Receptacle Wire Connections all vehicles except Precedent 3 3 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sense lead fuse to the onboard computer gray wire See following WARNING Page 8 18 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures A WARNING Do not bypass the sense lead fuse 3 4 Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms The resistanc
67. C Plug and Receptacle Onboard Computer AC Power and Continuity Test of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test ON Oo O1 2 0 N gt Continuity TEST PROCEDURE 1 BATTERY VOLTAGE AND DC PLUG AND RECEPTACLE See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Check the DC plug and the vehicle charger receptacle for damage dirt corrosion or any condition that might prevent a sound electrical connection 2 Inspectthe 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 red wire that connects to the positive post of battery no 1 Figure 5 2 Page 5 3 3 2 Carryall 2 and Turf 2 Verify that the 10 gauge red wire from the charger receptacle is connected to the positive post of battery no 1 Figure 5 2 Page 5 3 3 3 Verify the 10 gauge red wire of the charger receptacle is connected to the main harness red wire at three wire plug 3 4 Make sure the two nuts that secure the two 10 gauge black wires to the receptacle fuse assembly are tight Figure 5 8 Page 5 15 Page 5 14 2008 Export Battery Charger Maintenance and Service Manual
68. CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger See following WARNING A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 3 11 Page 3 13 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 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 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
69. CONTROLLER COMPUTER lt TERMINAL IN CHARGER e LEE e I 10 BLACK Noc IONER RED WIRES TO POSITIVE No 10 RED TERMINAL BLACK TO lt JONBOARD TERMINAL CHARGER BATTERIES Figure 4 2 Charge Circuit DS Villager 4 SOLID STATE ONBOARD SPEED CONTROLLER COMPUTER TERMINAL CHARGER VI RECEPTACLE No 10 RED RED TO No 10 RED POSITIVE Three Pin TERMINAL Connector BLACK TO f ONBOARD Teun CHARGER BATTERIES Figure 4 3 Charge Circuit Precedent Vehicles 2008 Export Battery Charger Maintenance and Service Manual Page 4 3 EXPORT POWERDRIVE CHARGER ONBOARD Charger Operation CHARGER OPERATION See General Warning Section 1 Page 1 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery char
70. DC cord wire only If any other reading is obtained the DC cord must be replaced 2008 Export Battery Charger Maintenance and Service Manual Page 6 21 ES EXPORT IQ PLUS CHARGER ONBOARD Test Procedures Transformer The IQ Plus battery charger transformer has two sets of coils a primary coil and a secondary coil Primary Coil 1 Cc BO NS 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 Remove the charger cover Disconnect the black wires marked 1 and 6 from the AC circuit breakers Disconnect the wires marked 2 3 4 and 5 from the voltage selector switch Place the continuity tester probes on the primary coil transformer wires disconnected above in pairs until all of the combinations in the following chart have been tested If the continuity readings agree with the chart replace the voltage selector switch If the continuity read ings differ from the chart replace the transformer PRIMARY COIL CONTINUITY NO CONTINUITY CHART NEGATIVE PROBE 1 2 3 4 5 6 1 C ntin ity Continuity M Cons CEU w 2 Contingit Continuity CE CU ou 2 Continuity Continuity eee CUN kee E 4 aay SNR MG Continuity Continuity o s 2 Say See TN Continuity Continuity B Coran Gaara CORN Continuity Continuity Secondary Coil 1 Disconnect the DC cord the AC cord from the
71. DC plug and cord Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 3 18 and Test Procedure 5 Charger DC Circuit Continuity Test on page 3 23 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 21 Gray sense lead fuse is blown not applicable to Precedent vehicles Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 3 18 Receptacle fuse link is blown not applicable to Precedent vehicles See Electrical Components section in the appropriate maintenance and 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 Test of AC Circuit on page 3 21 Internal AC breaker Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 21 Transformer primary coil Test Procedure 6 Transformer on page 3 24 Relay Test Procedure 8 Continuity on page 3 26 Failed ammeter Replace ammeter Relay closes and transformer hums but ammeter does not move Blown charger fuse Test Procedure 5 Charger DC Circuit Continuity Test on page 3 23
72. 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 and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 5 2 3 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 5 2 Page 5 3 and that the internal charger wiring is correct Figure 5 6 Page 5 9 TAN LIDE SWITCH ASSEMBLY pe BLACK 5 SECONDARY L SWITCH KES TAN r POSITION BLACK HEATSINK ASSEMBLY W DIODES FUSE ASSEMBLY TRANSFORMER E a PRIMARY 2 AMMETER BLACK BLUE ORDSET 3 BUSHING OUTPUT POLARITY RED POS 47 d TOP oUTPUT BLACK NEG ed CIRCUIT CORDSET BLUE COMMUNICATION BREAKER c BOTTO CIRCUIT OUTPUT BREAKER SUPPRESSOR PLUG GRE
73. DRIVE CHARGER ONBOARD Test Procedures Figure 4 6 Battery Voltage Test DS Villager 4 Test Procedure 1B Precedent Vehicles 1 Check the wire connections between the vehicle and battery charger Figure 4 3 Page 4 3 1 1 Verify that the 10 gauge red wire of the charger is connected to the positive post of battery no 1 1 2 Verify the connection of the 10 gauge black wires in the charger adapter harness One wire con nects to the onboard computer black lead wire The second wire connects to the charger receptacle black lead wire 1 3 Verify the connection of the 18 gauge gray wires in the charger adapter harness One wire con nects to the onboard computer The second wire connects to the charger receptacle gray lead wire 2 Style A and B 4 x 12 Volt Precedent 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 LS FRONT OF VEHICLE 200 DCV SETTING Figure 4 7 Battery Voltage Test Precedent Style A Figure 4 8 Battery Voltage Test Precedent Style B Battery Configuration Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 RED probe to battery no 1 1 RED probe to battery no 1 2 BLACK probe to battery no 4 2 BLACK probe to battery no 4 Page 4 12 2008 Export Bat
74. E TO DC CORD CONTROL BOARD BLACK WIRE e CMM OD Sui RANTS STRAIN RELIEF BUSHING DC CORD Figure 6 17 DC Cord Figure 6 18 DC Cord Replacement DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base Page 6 24 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Charger Repairs EN 2 Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18 in Ib 2 0 N m Figure 6 17 Page 6 24 3 Attach the blue wire of the new DC cord to the control board Figure 6 17 Page 6 24 4 Attach black wire of the new DC cord to ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the inside nut 2 tighten the outside nut 1 1 4 turn Figure 6 18 Page 6 24 See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Tie the wires together as they were before the wire ties were removed See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 7 Position the charger cover on the base Install the mounting scre
75. EDURE 2 CONTROL BOARD See General Warning Section 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 A 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 probe of multimeter on terminal with blue DC cord wire and red probe to terminal with red relay wire Figure 6 6 Page 6 12 BLUE WIRE RED WIRE TO DC 7 TO RELAY CORD 500 DCV SETTING A BLACK WIRE WHITE OR BLUE FROM RELAY WIRE FROM AC CORD 200 DCV SETTING Figure 6 6 DC Circuit Test Figure 6 7 AC Circuit Test 3 Multimeter should indicate full battery voltage approximately 47 50 volts If reading is incorrect replace control board AC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and 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 A 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 te
76. EEN or GREEN YELLOW CASE GROUND BLACK BLACK BLACK 1 AC CIRCUIT BREAKERS BLACK TAN 6 TERMINAL AC VOLTAGE SELECTOR SWITCH Figure 6 4 Export IQ Plus Onboard Battery Charger Wiring Diagram Page 6 6 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Checking Battery Condition with an Onboard Charger 6 CHECKING BATTERY CONDITION WITH AN ONBOARD CHARGER Read DANGER WARNING and CAUTIONS beginning on page 6 3 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ Plus vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illu minate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart See Trouble shooting on page 6 7 If the specified test procedures identify no problems plug the AC cord into a wall out let and let it charge until the charger shuts off automatically If a problem is found correct it and charge the vehicle Normal battery voltage near the end of a charge cycle should be approximately 59 to 63 volts DC while the charger is still operating START CHARGE CYCLE 1 Disconnect the
77. EN YELLOW H CURRENT LIMITER Figure 5 6 Export IQ Plus Battery Charger Wiring Diagram External Charger 2008 Export Battery Charger Maintenance and Service Manual Page 5 9 a EXPORT IQ PLUS CHARGER EXTERNAL Troubleshooting TROUBLESHOOTING See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 A 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 A WARNING 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 25880 18 The Troubleshooting Guide encompasses the entire battery charging cir cuit Test procedures specified in the Troubleshooting Guide can be found on the following pages Page 5 10 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Troubleshooting p EXPORT IQ PLUS BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no tr
78. ETTING ON AC VOLTAGE MINIMUM AC VOLTAGE MAXIMUM AC VOLTAGE SELECTOR SWITCH PERMITTED PERMITTED 100 Volts AC 95 105 200 Volts AC 190 210 220 Volts AC 209 231 240 Volts AC 228 252 5 Check continuity of the AC circuit 5 1 Remove the charger cover 5 2 Bypass the relay 5 2 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 3 11 Page 3 13 5 2 2 Disconnect the brown wire from relay terminal 6 5 2 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 5 2 4 Disconnect the black wire from relay terminal 7 5 2 5 Disconnect the blue wire from relay terminal 4 5 2 6 Use a jumper wire with alligator clips to connect the black wire from relay terminal 7 to the blue wire from relay terminal 4 5 3 With relay bypassed there should be continuity across the AC cord blades Figure 3 20 Page 3 22 2008 Export Battery Charger Maintenance and Service Manual Page 3 21 ES EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures AC plug may have different appearance depending on geographic region Figure 3 20 AC Cord Test If the circuit is not complete check the wiring of the AC cord 16 transformer primary coil wires 21 internal AC circuit breakers 13 voltage selector switch 9 and jumper wires Figure 3 12 Pag
79. EXPORT Powertirive oo IQ BATTERY CHARGERS plu c3 2008 MAINTENANCE amp SERVICE MANUAL Manual No 103373122 Edition Code 0408A00000 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 p
80. Ensure that the charger and vehicle are wired properly and all connections are clean and tight TEST PROCEDURE 5 CHARGER DC CIRCUIT CONTINUITY TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 2008 Export Battery Charger Maintenance and Service Manual Page 3 23 ES EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Using a continuity tester CCI P N 1011273 or multimeter CCI P N 1011480 set to 200 ohms connect the test probes to the pins marked and on the DC plug Figure 3 23 Page 3 24 Note the read ing 3 Reverse the test probes and check the DC plug again Figure 3 24 Page 3 24 The circuit should show continuity in only one direction 4 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 3 26 Also check the diodes heatsink See Test Procedure 4 Diodes on page 3 22 POSITIVE PIN POSITIVE PIN m PULL HERE NL emm ULE IEHE aS NEGATIVE PIN NEGATIVE PIN Figure 3 23 DC Plug Test Figure 3 24 DC Plug Test Reversed Probes 5 If the circuit shows continuity in both directions a short circuit exists in the charger DC circuit usually caused by failed diodes See T
81. Failed on page 5 19 Charger output is low One diode failed Test Procedure 4A Single Diode Failure on page 5 18 Transformer coil short circuit failure Test Procedure 6 Transformer on page 5 20 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 17 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 17 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 17 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 5 22 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 17 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 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 intervals with DC charger cord plugged in 25 seconds at
82. HART NEGATIVE PROBE 1 2 3 4 5 6 1 Continuity Continuity ere NOME SUD w Continuity Continuity m EU NL 3 Continuity Continuity EU T Gori E OL Con UR CHRON Continuity Continuity o z z Conn Mire EM Gontinuity Continuity 6 Suny Sin NN Continuity Continuity Secondary Coil 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove the transformer tan secondary coil wire from the upper terminal of the heatsink Figure 3 11 Page 3 13 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 and each of the secondary coil wires tan The tester should indicate continuity on both secondary coil wires If tester does not indicate continuity on both secondary coil wires replace transformer Ensure that the fuse is intact and not blown Page 3 28 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures Voltage Suppressor Failed Closed 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Using a multimeter set to the diode test function place the black probe of the multimeter on the s
83. IQ PLUS CHARGER ONBOARD Test Procedures 6 6 Make sure that the voltage selector switch on the back of the charger is set for the appropriate incoming AC voltage Also ensure that the secondary coil wires are not touching one another With the relay bypassed insert the AC plug into an outlet If the AC line fuse blows or AC circuit breaker trips the trans former is shorted internally and must be replaced 7 Ifthe AC line fuse does not blow or the AC circuit breaker does not trip check the transformer secondary coil voltage 8 Disconnect AC cord from the wall outlet 9 Using alligator clips and a multimeter set to 500 volts AC connect the multimeter probes to the second ary transformer coil tan wires Figure 6 12 Remove Secondary Coil Wires From Heatsink 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 Ifthe voltage reading is normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuity of the DC circuit See Test Procedure 5 Charger DC Circuit Continuity Test on page 6 16 12 When troubleshooting and repairs are complete remove jumper wire and properly connect relay wiring See following WARNING A WARNING
84. LUS CHARGER ONBOARD Troubleshooting 6 IQ PLUS ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Charger output is low One diode failed Test Procedure 4A Single Diode Failure on page 6 14 Transformer coil short circuit failure Test Procedure 6 Transformer on page 6 16 Onboard computer malfunction Test Procedure 2 Control Board on page 6 12 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 6 13 Onboard computer malfunction Test Procedure 2 Control Board on page 6 12 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 6 18 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Control Board on page 6 12 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 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 four second intervals AC power interrupted Test Procedure 3 AC Powe
85. Manual 8 continuity AC circuit breaker sseeeseeee 3 29 ACE CONG coiere teo een t pectet uas 3 26 ammeter 2 Rede 3 29 DC cord edet 3 27 relay ier LR TEATE 3 29 transformer eseseeenennee 3 28 voltage suppressor ccce 3 29 transformer installation 3 32 KEMOVA 2 4 B bep us 3 32 tesilng eee eU R 3 24 3 28 troubleshooting eese 3 14 voltage suppressor installation 3 34 removal ccc cece tied ete eae cde ced dae dots 3 34 testing cnius evite 3 29 PowerDrive charger onboard AC cord short installation 2 item 4 32 removal sw sashes e eee ee ipe 4 32 ammeter installation iiiki nii 4 29 remoVal e erea a ERR a 4 29 testing ett hs ens a eed ee cde feo pe agen 4 25 batteries battery condition after a charge cycle 4 8 charging batteries that have low voltage 4 33 state of charge test 4 20 battery charger charger features ssssssssss 4 2 installation re 4 36 4 37 operation e 4 5 removal esce er eere etras 4 35 4 36 je E pri EE ERES 4 26 iu C 4 6 battery warning light ssesssessssss 4 2 charge circuit ssssssseese 4 2 charge interlock enneren 4 2 circuit breaker installation scsi 3 ect 4 31 removal wien ae ipe 4 31 TESTING c 4 26 control board testing see elie Gane ee 4 13 cord charger see AC cord or
86. N m Page 6 34 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Onboard Charger Removal and Installation 6 VILLAGER 6 VILLAGER 8 TRANSPORTER 4 TRANSPORTER 6 CARRYALL 6 TURF 2 252 CARRYALL 2 252 XRT 900 Figure 6 23 Onboard Charger Mounting Details 2008 Export Battery Charger Maintenance and Service Manual Page 6 35 INDEX battery condition after a charge cycle 5 8 breaker charger circuit see circuit breaker The following index is grouped in sections one sec tion for each type of battery charger in the manual Make sure that the battery charger has been prop erly identified before using the index See Battery X charge circuit cece et ee teeteeeenees 5 3 Charger Identification Section 2 Page 2 6 circuit breaker installation en ettet 5 33 A r moVal teer Ren RUPES 5 32 AC charger receptacle UT e 5 27 installation oem eite ce De ade eec aa 8 5 33 cord charger removal 3 5 bent tete eere cs 5 33 See AU con OrDC cord COIT MM NI a Ea 5 22 5 23 deut AC cord installation cnet 5 28 TESTING usi tenis ectetuer oti pue e
87. Page 1 1 See additional WARNING on page 3 1 Charger Relay Removal 1 OW LE ER DS Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 3 30 Remove the charger cover Disconnect all wires from the relay Figure 3 30 Page 3 35 Remove the two screws and nuts attaching relay to relay mounting bracket Figure 3 30 Page 3 35 Remove the relay AC CIRCUIT BREAKERS Figure 3 30 Charger Relay Charger Relay Installation Install in reverse order of removal Connect wires as shown Figure 3 11 Page 3 13 Tighten hardware securing relay to relay mounting bracket to 18 in Ib 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 OV dee c m 6 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 3 30 Remove the charger cover Disconnect the two black wires attached to top circuit breaker Figure 3 11 Page 3 13 Disconnect the two black wires attached to bottom circuit breaker 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 Repeat step 5 for the removal of the bottom circuit breaker AC Circuit Breaker Installation Install in reverse order of removal 2008 Export Battery Charger Maint
88. Page 4 27 Using pliers squeeze the strain relief bushing and remove the DC cord Figure 4 23 Page 4 27 DC Cord Installation 1 2 Insert the leads of the new DC cord through the hole in the charger base Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18 in Ib 2 0 N m Figure 4 23 Page 4 27 Attach the blue wire of the new DC cord to the control board Figure 4 23 Page 4 27 4 Attach black wire of the new DC cord to ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the inside nut 2 tighten the outside nut 1 1 4 turn Figure 4 24 Page 4 27 See following CAUTION Page 4 26 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Charger Repairs DC CORD BLUE WIRE TO DC CORD CONTROL BOARD BLACK WIRE ul RED WIRE ES i TO HEATSINK STRAIN RELIEF BUSHING Figure 4 23 DC Cord Figure 4 24 DC Cord Replacement CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Using pliers put the strain relief bushing on the cord and insert it into the charger base 6 Tie the wires together as they were before the wire ties were removed See following WARNING A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could re
89. Page 5 13 4 Remove the two red wires from the heatsink 5 Remove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Place heatsink against charger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts that secure the heatsink to the case Tighten the bolts to 22 in Ib 2 5 N m Figure 5 6 Page 5 9 and Figure 5 7 Page 5 13 Page 5 28 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL 2 Connect the red wire from the DC cord and the red wire from the charger relay to the center terminal post on the heatsink Tighten nut to 18 in Ib 2 0 N m Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the other secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Install the charger cover and check charger for proper operation TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Transformer Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 5 27 Remove the charger cover 3 Note the locations of wire ties and remove the wire ties 4 Disconnect the black primary coil leads from the AC circuit breakers and the voltage selector switch
90. RMITTED 100 Volts AC 95 105 200 Volts AC 190 210 220 Volts AC 209 231 240 Volts AC 228 252 5 Check continuity of the AC circuit 5 1 Remove the battery charger from 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 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 6 4 Page 6 6 If the charger is wired correctly check the continuity of the AC cord AC cord reel transformer primary coil and the internal AC circuit breaker individually See Test Procedure 8 Continuity on page 6 18 2008 Export Battery Charger Maintenance and Service Manual Page 6 13 EN EXPORT IQ PLUS CHARGER ONBOARD Test Procedures 8 When troubleshooting and repairs are complete properly connect the relay wiring See following WARNING A 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 AC plug may have different appearance depending on geographic region Figure 6 9 AC Cir
91. RRME EO unas 5 9 Tro bleshootlld tieu Me REM Mi 5 10 Test Procedures ssc tue La tte ees 5 14 Index of Test Procedures x ie m ng endet aut n e OLIM a REIR na gre d edge ster lad 5 14 Charger Repairs E nace 5 27 DG CONG np 5 27 Heatsinkc zou MILD b REM 5 28 TEAISTORTTIOE econtra a 5 29 AMEE d ad ated d aat ad teda edes 5 30 Fuse Elnk hito uai tiet baee toe 5 31 Voltage SUPPIeSSOM 5 e ett a Dette eb e tdeo civi net De bu da uult alat b ada 5 31 lerra EA 5 32 Charger AC Circuit Breakers screen eth tnnt rnnt a ka nante eaten 5 32 AG Charger Receptacle buen ui 5 33 Charging a Battery Pack that has Low Voltage sse 5 34 SECTION 6 EXPORT IQ PLUS CHARGER ONBOARD General IrfOrfri amp tlOI cuocere prie Tee ette pne RR E EA d MESA Fa RR Ae eR uda 6 1 IQ Plus Onboard Charger Features sssssssssssseneeeee eee mmn en nnn nnne 6 2 Battery Wamirng Light iro oie edel fine ree A EO HR Ra eU a EO ERE M eae pini e Ud 6 2 The Charge Circuit me 6 2 Onboard Charger Operation eserine eian ieee a iaer aaa A a nennen nennen nn 6 3 Onboard Charger AC Power Connection sssssssssseeseeenenee eene enne 6 4 Charging Batteries s m oia E ate ibe aie tinted tite dv eniin 6 5 Testing Charger Operation 20 2 cccccccecececceeeeececceeeenecceeeenscaeeeeensuceedeeeseceedeesneeacdenesseaceedeeneeaeeeneneeas 6
92. Test Procedure 5 Charger DC Circuit Continuity Test on page 3 23 11 When troubleshooting and repairs are complete remove jumper wire and properly connect relay wiring See following WARNING A 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 See additional WARNING on page 3 1 2008 Export Battery Charger Maintenance and Service Manual Page 3 25 ES EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures 1 With the batteries fully charged disconnect the DC charger plug for approximately 20 seconds and reconnect it The ammeter should jump to a reading between 14 and 18 amps and taper to below 5 amps within 15 minutes If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 Onboard Computer on page 3 21 See following NOTE NOTE Batteries near the end of their useful lives may not allow the battery charge current to taper below 5 amps See Section 13 Batteries in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 See additional WARNING on p
93. ade If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other If the correct readings are obtained in all of the previous steps the short AC cord and the retractable cord reel are functioning properly If any of the readings are incorrect proceed to the following test procedures to determine which of the two components has failed Page 6 18 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Test Procedures 6 nr Figure 6 13 AC Cord and Retractable Cord Reel Continuity Test Short AC Cord without Retractable Cord Reel Check continuity of the short AC cord without the retractable cord reel 1 Disconnect the 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 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 Figure 6 14 Heatshrink Removal 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 2008 Export Battery Charger Maintenance and Service Manual Page 6 19 E EXPORT IQ PLUS CHARGER ONBOARD Test Procedures Figure 6 15
94. age 3 1 AC Cord 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect green yellow wire 2 from charger case and position it so it does not touch any metal 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 on one flat blade only If any other reading is obtained the AC cord and plug must be replaced Place the red probe on the end of the green yellow wire 2 and with the black probe check for con tinuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only the ground pin If any other reading is obtained the AC cord and plug must be replaced Place red probe on the blue wire and check for continuity on both flat blades and on the round pin of the AC plug The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord and plug must be replaced 200 OHM SETTING AC plug may have different appearance depending on geographic region Figure 3 26 AC Plug Page 3 26 2008 Expo
95. age 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 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 An AC circuit test should be done before performing this test procedure to ensure the continuity of the AC cord AC cord reel internal AC circuit breakers and charger wiring See Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 6 13 1 ak wD Disconnect AC cord from the wall outlet Remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 Remove the charger cover Disconnect transformer secondary coil wires from the heatsink Figure 6 12 Page 6 17 To apply AC power directly to the transformer primary coil bypass the relay See Charging a Battery Pack that has Low Voltage on page 6 31 See following DANGER A 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 Page 6 16 2008 Export Battery Charger Maintenance and Service Manual EXPORT
96. all outlet 2 Remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 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 6 14 Page 6 19 4 Disconnect the short AC cord from the retractable cord reel 5 Using a multimeter set for 200 ohms place the red probe in one of the flat blade openings of the cord reel receptacle 1 Figure 6 16 Page 6 21 Test for continuity at the cord reel AC plug 2 on each of the flat blades and then 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 cord reel must be replaced Page 6 20 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Test Procedures 6 200 OHM SETTING Figure 6 16 Retractable Cord Reel Test 6 Place the red probe into the other flat blade opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then 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 cord reel must be replaced 7 Place the red probe into the top center opening of the cord reel receptacle 1 Test for continuity on the cord reel AC plug 2 on each of the flat blades and then on the round pi
97. allation Install in reverse order of removal AC CHARGER RECEPTACLE See General Warning Section 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 Remove the charger cover Disconnect the two black wires from the AC charger receptacle Figure 5 6 Page 5 9 Disconnect the green yellow wire from the AC charger receptacle ak WN Press the retaining tabs on the top and bottom of the AC charger receptacle and remove the AC charger receptacle from the font of the charger AC Charger Receptacle Installation 1 Press the AC charger receptacle into the opening in the front panel of the battery charger 2 Connect the green yellow ground wire to the center terminal of the AC charger receptacle 3 Connect the two black wires to the bottom terminals of the AC charger receptacle 4 Install the charger cover 2008 Export Battery Charger Maintenance and Service Manual Page 5 33 a EXPORT IQ PLUS CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger See following WARNING A WARNING Knowledge of battery charger wirin
98. and black wire from terminal 7 of the relay Figure 6 20 Page 6 29 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 and the relay must be replaced 5 Connect charger DC cord to 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 Remove the charger cover Disconnect the black wire from the left ammeter post as viewed from inside the charger Place the continuity tester clip on one of the ammeter posts 9v Go Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker 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 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 d
99. and secure wiring could result in vehicle malfunction property damage 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 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 Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 A 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 2008 Export Battery Charger Maintenance and Service Manual Page 1 3 SAFETY General Warning Figure 1 1 Precedent Battery Configuration Style A Figure 1 2 Precedent Battery Configuration Style B 4x 12 Volt Batteri
100. ansformer hum and ammeter does not move Batteries disconnected Connect batteries See Figure 5 9 Page 5 16 Battery voltage is too low Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 14 Poor connection between plug and receptacle Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 14 DC plug and cord Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 14 and Test Procedure 5 Charger DC Circuit Continuity Test on page 5 20 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 5 17 Gray sense lead fuse is blown not applicable to Precedent vehicles Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 5 14 Receptacle fuse link is blown not applicable to Precedent vehicles See Electrical Components section in the appropriate maintenance and 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 Improper AC outlet voltage Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 17 not move Failed AC plug and cord Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 17 Internal AC breaker Test Procedure 3 AC Power and Continuity Test of AC
101. ansporter 4 and 6 Villager 6 and 8 18 GRAY 18 GRAY WORED Turf2and252 SENSE LEAD FUSE Carryall 2 and 252 XRT 900 BATTERIES Figure 5 2 Charge Circuit 2008 Export Battery Charger Maintenance and Service Manual Page 5 3 a EXPORT IQ PLUS CHARGER EXTERNAL External Charger Installation and Operation EXTERNAL CHARGER INSTALLATION AND OPERATION See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Do not bypass the sense lead fuse 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 three wire outlet of the proper voltage and frequency as shown on the charger
102. anual Page 6 32 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Charging a Battery Pack that has Low Voltage 6 DC CORDSET DIODES WITH HEATSINK SECONDARY COIL LY MESA ak BLACK FUSE AMMETER CONTROL BOARD PRIMARY COIL TRANSFORMER MNU AC CORD WHITE or BLUE BLACK or BROWN GREEN or GREEN YELLOW RELAY BYPASS RELAY BYPASS JUMPER WIRE JUMPER WIRE CASE GROUND BLACK BLACK 1 AC CIRCUIT BREAKERS BLACK 4 TAN 6 TERMINAL BLACK 6 AC VOLTAGE SELECTOR SWITCH Figure 6 22 IQ Plus Onboard Charger Wiring Diagram Relay Bypassed 2008 Export Battery Charger Maintenance and Service Manual Page 6 33 ES EXPORT IQ PLUS CHARGER ONBOARD Onboard Charger Removal and Installation ONBOARD CHARGER REMOVAL AND INSTALLATION See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 6 4 Page 6 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 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 6 23
103. are identified on the plug If tester does not indicate continuity the DC cord must be replaced 8 Place the continuity test probe on the negative pin of the DC plug The 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 17 of the DC cord 11 Place the continuity test probe on the negative pin of the DC plug The tester should indicate conti nuity If tester does not indicate continuity the DC cord 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 Figure 5 19 DC Cord Relay and Limiter Transformer The IQ Plus battery charger transformer has two sets of coils a primary coil and a secondary coil Primary Coil 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the black wires marked 1 and 6 from the AC circuit br
104. arger if it has received a sharp blow was dropped or otherwise damaged in any way Make sure it is operating properly before putting it back in use Have worn cut or damaged power cords or wires replaced immediately Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will 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 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 6 3 Page 6 5 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 with your charger has the proper AC plug for your location If it does not contact your Club Car repr
105. at has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor The IQ Plus battery charger is automatic and has no external controls Figure 5 1 Page 5 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 the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer OBC records the amount of energy consumed as the vehicle is used then directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger shuts off automatically preventing the possibility of either undercharging or overcharging Figure 5 1 IQ Plus External Charger Export Model 25880 11 2008 Export Battery Charger Maintenance and Service Manual Page 5 1 a EXPORT IQ PLUS CHARGER EXTERNAL General Information IQ PLUS EXTERNAL CHARGER FEATURES Charge Interlock IQ Plus battery charger DC plugs have three pins rather than two blades common on most standard charger plugs Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead that is the communication link between the charger and the onboard computer When the charger plug is plugged into the vehicle rec
106. battery voltage near the end of a charge cycle should be approximately 59 to 63 volts DC while the charger is still operating Start Charge Cycle 1 Disconnect the AC plug from the wall outlet 2 Wait 20 seconds then reconnect the AC cord to the wall outlet 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 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 will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle continues If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 5 Page 4 7 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the
107. ce and Service Manual Page 4 9 EXPORT POWERDRIVE CHARGER ONBOARD Troubleshooting EXPORT POWERDRIVE ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Both charger fuse links blow or receptacle fuse link blows Battery is wired in reverse polarity Check vehicle wiring DC cord is wired in reverse polarity Check battery charger wiring Both diodes failed Test Procedure 4B Both Diodes Failed on page 4 17 Charger output is low One diode failed Test Procedure 4A Single Diode Failure on page 4 16 Transformer coil short circuit failure Test Procedure 6 Transformer on page 4 19 Onboard computer malfunction Test Procedure 2 Control Board on page 4 13 Charger turns off too soon AC power supply was shut off Test Procedure 3 AC Power and Continuity Check of AC Circuit on page 4 15 Onboard computer malfunction Test Procedure 2 Control Board on page 4 13 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 4 20 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Control Board 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
108. ce multimeter black probe here Place multimeter red probe here black probe here EY S 2 Z3 TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES Figure 5 9 IQ Plus Battery Configuration Page 5 16 2008 Export Battery Charger Maintenance and Service Manual Test Procedures EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures EN TEST PROCEDURE 2 ONBOARD COMPUTER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to This will ensure that AC power is present 2 Check the AC circuit breakers on the front of the charger and reset it if necessary 3 Insertthe DC cord from the second charger into the receptacle of the vehicle that is not charging properly 4 Ifthe second charger fails in the same manner as the first charger then the vehicle charging circuit is not functioning properly See Troubleshooting on page 5 10 5 Connect the first charger into another vehicle that is known to be functioning properly If the charger per forms as it should then the charger is 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 plu
109. charger output being low open circuit diode If a diode has failed the entire heatsink must be replaced To check diodes 1 8 Disconnect 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 charger cover 4 5 Disconnect one transformer secondary coil wire from the diode terminal Figure 4 14 Page 4 17 Using a low voltage continuity tester or multimeter set to the 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 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 with diodes must be replaced If a diode does not conduct current does not show continuity in either direction the entire heatsink must be replaced On rare occasions a single fuse link may blow due to excessive heat This can be caused by a loose internal fuse connection Check all three fuse connections inside the charger to be sure they are clean and tight The proper tightness for the fuse link connections is 22 in Ib 2 5 N m Ensure the charger is wired properly and all connections are clean and tight See following CAUTION CAUTION If connections are
110. connects to the negative post of battery no 4 The red wire of the charger is connected to the positive post of battery no 1 The blue wire sense lead from the charger is connected through a 3 way wire adapter at the sense lead fuse to the gray wire that connects the charger receptacle to the onboard computer Page 4 2 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD The Charge Circuit Precedent Vehicles The 10 gauge black wire from the charger becomes two wires in the adapter harness Figure 4 3 Page 4 3 One wire connects to the onboard computer black lead wire The second wire connects to the charger recep tacle black lead wire The 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 Figure 4 7 Page 4 12 and Figure 4 8 Page 4 12 or battery no 6 Figure 4 9 Page 4 13 The 10 gauge red wire of the charger is connected to the positive post of battery no 1 The 18 gauge gray wire from the charger becomes 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 SOLID STATE ONBOARD ce SPEED
111. cuit Continuity Test TEST PROCEDURE 4 DIODES Use Test Procedure 4A Single Diode Failure on page 6 14 for single diode failures and testing of individual diodes If both diodes have failed use Test Procedure 4B Both Diodes Failed on page 6 15 Test Procedure 4A Single Diode Failure See General Warning Section 1 Page 1 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 ak wn Disconnect AC cord from the wall outlet Remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 Remove the charger cover Disconnect one transformer secondary coil wire from the diode terminal Figure 6 10 Page 6 15 Using a low voltage continuity tester or multimeter set to the 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 6 10 Page 6 15 Reverse test probes and check each diode again and note the reading Figure 6 11 Page 6 15 A diode is designed to conduct current in one direction only If a diode conducts current shows continuity in both directions the entire heatsink with diodes must be replaced If a diode does not conduct current does not show continuity in either direction the entire heatsink must be r
112. cuit 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 2008 Export Battery Charger Maintenance and Service Manual Page 4 31 EXPORT POWERDRIVE CHARGER ONBOARD Charger Repairs CHARGER AC CORD AND RETRACTABLE CORD REEL See General Warning Section 1 Page 1 1 Short AC Cord Removal 1 ONS e cos ND 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 4 35 See WARNING on page 4 26 Remove the charger cover Disconnect the AC cord black wire from the AC circuit breaker Figure 4 26 Page 4 31 Disconnect the AC cord white wire from the control board Disconnect the AC cord green wire from the charger base Figure 4 26 Page 4 31 Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger Short AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Figure 4 26 Page 4 31 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 Ib 2 0 N m 3 Position the strain relief bushing on the AC cord 4
113. d Charger Removal on page 4 35 See WARNING on page 4 26 Remove the charger cover Disconnect all wires from the relay Figure 4 26 Page 4 31 Remove the two screws and nuts attaching relay to mounting bracket MES Remove the relay Page 4 30 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Charger Repairs Charger Relay Installation Install in reverse order of removal Connect wires as shown Figure 4 26 Page 4 31 Tighten nuts securing relay to mounting bracket to 18 in Ib 2 0 N m CONTROL BLUE WIRE TO CHARGER RELAY P UG eee AC Cl BREAKE AC CORD b BOTTOM VIEW OF RELAY m STRAIN RELIEF M BUSHING i BLACK WIRES TO BLACK OR PRIMARY COIL BROWN WIRE GREEN TOCONTROL OR BLACK WIRES BOARD GREEN TO VOLTAGE YELLOW INPUT SWITCH GROUND WIRE Figure 4 26 Charger Relay CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 AC Circuit Breaker Removal 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 4 35 See WARNING on page 4 26 Remove the charger cover Disconnect the two black wires attached to top circuit breaker Figure 4 26 Page 4 31 Disconnect the two black wires attached to bottom circuit breaker Oi dme O N With a pair of pliers squeeze in the retaining tabs on the sides of the top AC cir
114. d Figure 3 12 Page 3 17 Disconnect the two tan secondary coil transformer wires from heatsink Disconnect the two black secondary coil transformer wires from the fuse 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 Ib 3 2 N m Figure 3 12 Page 3 17 Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Connect one secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Connect the other secondary coil transformer wire tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 6 Connectthe black primary coil transformer wire marked 1 to the top terminal of the top AC circuit breaker 7 Connect the black primary coil transformer wire marked 6 to the top terminal of the bottom AC circuit 10 breaker Connect each of the remaining black primary coil transformer wires marked 2 3 4 and 5 to the corre sponding terminals marked on the voltage selector switch Set the voltage selector switch to the appropriate voltage matching the incoming AC el
115. d and the relay must be replaced 4 Remove the black wire from terminal 4 of the relay and black wire from terminal 7 of the relay Figure 4 26 Page 4 31 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 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 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 4 35 Remove the charger cover Disconnect the black wire from the left ammeter post as viewed from inside the charger Place the continuity tester clip on one of the ammeter posts Qu dm eU NO Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter 2008 Export Battery Charger Maintenance and Service Manual Page 4 25 EXPORT POWERDRIVE CHARGER ONBOARD Charger Repairs AC Circuit Breaker 1 Disconnect the DC cord the AC cord from the wall outlet and remove the battery charger from the vehi cle See Onboa
116. d on the DS Villager 4 Model number 17790 40 is used on Precedent golf cars Depending on the geographic region the charger provided with your vehicle may be a different model Do not attempt to service a battery charger that has not been properly identified If a charger cannot be prop erly identified contact your local Club Car dealer or distributor For battery chargers 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 vehicle is used then directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger shuts off automatically preventing the possibility of either undercharging or overcharging See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge Figure 4 1 Export PowerDrive Onboard Battery Charger 2008 Export Battery Charger Maintenance and Service Manual Page 4 1 EXPORT POWERDRIVE CHARGER ONBOARD The Charge Circuit POWERDRIVE
117. 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 A CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections 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 See fol lowing NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately CHECKING BATTERY CONDITION WITH AN EXTERNAL CHARGER See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With the IQ Plus vehicles this is not necessary the onboard computer controls and monito
118. dditional WARNING on page 3 1 A 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 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 3 11 Page 3 13 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 PowerDrive external battery chargers model numbers 18780 11 and 18780 18 The Troubleshooting Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages Page 3 14 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Troubleshooting EXPORT POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer hum and ammeter does not move Batteries disconnected Connect batteries See Figure 3 2 Page 3 3 through Figure 3 7 Page 3 8 Battery voltage is too low Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 3 18 Poor connection between plug and receptacle Test Procedure 1 Battery Voltage and DC Plug and Receptacle on page 3 18
119. dditional WARNING on page 3 1 To check the diodes use Test Procedure 4A Single Diode Failure on page 3 22 If both diodes have failed closed both charger fuse links 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 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 connected to the relay coil and the DC cord black wire should be connected to the left side of the ammeter when viewed from inside the charger Figure 3 11 Page 3 13 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 On rare occasions both diodes may fail as a result of a lightning strike at the charging location 4 Excessive heat due to a loose connection may also cause both fuse links to blow Be sure fuse connec tions are tightened to 22 in Ib 2 5 N m 5
120. del number printed on the charger Refer to the appropriate section of this manual as indicated in the chart below for information on troubleshooting and repairing the battery charger Do not attempt to service a battery charger that cannot be properly identified If a charger cannot be identified contact your local Club Car dealer or distributor BATTERY CHARGER NAME REFER TO AND MODEL NUMBER Export PowerDrive External Battery Charger 18780 11 101831503 Section 3 Export Power Drive Battery Charger Exter Export PowerDrive External Battery nal Charger 18780 18 101831504 Export PowerDrive Onboard Battery Charger 17790 10 101831601 Export PowerDrive Onboard Battery Charger g TOU TII 1891508 Section 4 Export Power Drive Charger Onboard Export PowerDrive Onboard Battery Charger 17790 12 101831603 Export PowerDrive Onboard Battery Charger 17790 40 102546902 Export IQ Plus External Battery Charger 25880 11 102892901 Section 5 Export IQ Plus Charger External Export IQ Plus External Battery Charger 25880 18 102892902 Export IQ Plus Onboard Battery Charger Section 6 Export IQ Plus 25660 40 102893001 Charger Onboard Page 2 6 2008 Export Battery Charger Maintenance and Service Manual SECTION 3 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL A DANGER See General Warning Section 1 Page 1 1 A WARNING
121. e 3 17 If the charger is wired correctly check the continuity of the AC cord transformer primary coil internal AC circuit breakers and the jumper wires individually See Test Procedure 8 Continuity on page 3 26 When troubleshooting and repairs are complete remove the jumper wire and properly connect the relay wiring See following WARNING A 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 4 DIODES Use Test Procedure 4A Single Diode Failure on page 3 22 for single diode failures and testing of individual diodes If both diodes have failed use Test 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 from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 4 Using a low voltage continuity tester or multimeter set to the diode test function connect the red test Disconnect one transformer seconda
122. e 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 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 DC CORD BLUE WIRE TO BLUE WIRE OF VOLTAGE SUPPRESSOR ASSEMBLY CONNECTED TO RELAY DC CORD BLACK WIRE TOAMMETER RED WIRE TO HEAT SINK Figure 3 27 DC Cord 2008 Export Battery Charger Maintenance and Service Manual Page 3 27 Test Procedures EN EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures Transformer The PowerDrive battery charger transformer has two sets of coils a primary coil and a secondary coil Figure 3 11 Page 3 13 Primary Coil 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the black wires marked 1 and 6 from the AC circuit breakers 4 5 Place the continuity tester probes on the primary coil transformer wires disconnected above in pairs until Disconnect the wires marked 2 3 4 and 5 from the voltage selector switch all of the combinations in the following chart have been tested If the continuity readings agree with the chart replace the voltage selector switch If the continuity read ings differ from the chart replace the transformer PRIMARY COIL CONTINUITY NO CONTINUITY C
123. e additional WARNING on page 5 1 A WARNING e Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 5 6 Page 5 9 e Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle DC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See preceding WARNING 2 Remove the charger cover 3 Remove the DC cord black wire 17 from the ammeter by loosening the nut Support the terminal as the nut is loosened to prevent rotation of the connection Figure 5 19 Page 5 25 4 Remove nut attaching the red wire 19 of DC cord onto the heatsink 2008 Export Battery Charger Maintenance and Service Manual Page 5 27 ESI EXPORT IQ PLUS CHARGER EXTERNAL Charger Repairs 5 Disconnect the DC cord blue wire 18 from the limiter 15 which connects to the red wire assembly that connects to the charger relay 6 Remove the wire ties that secure the blue wire 18 to the black transformer wire Note the location of the wire ties 7 Using pliers squeeze the strain relief bushing and remove the DC cord DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base 2 Attach the red wire of the new DC cord to the center terminal of the
124. e branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock WARNING CONTINUED ON NEXT PAGE 2008 Export Battery Charger Maintenance and Service Manual Page 6 3 E EXPORT IQ PLUS CHARGER ONBOARD Onboard Charger Operation Do not use an extension cord 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 charger dry Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not use a battery charger if the cord or plug 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 operate the ch
125. e 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 and remove the battery charger from the vehi cle See Onboard Charger Removal on page 6 34 See WARNING on page 6 24 2008 Export Battery Charger Maintenance and Service Manual Page 6 29 6 EXPORT IQ PLUS CHARGER ONBOARD Charger Repairs 2 Remove the charger cover 3 Disconnect the AC cord black wire from the AC circuit breaker Figure 6 20 Page 6 29 4 5 Disconnect the AC cord green wire from the charger base Figure 6 20 Page 6 29 6 Disconnect the AC cord white wire from the control board Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger Short AC Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole in the charger face Figure 6 20 Page 6 29 Connect the black wire and white wire to the control board Figure 6 4 Page 6 6 Connect the green wire to the charger base Tighten the screw on the green ground wire terminal to 18 in Ib 2 0 N m Position the strain relief bushing on the AC cord 4 Using pliers install the strain relief bushing and AC cord into the mounting hole in th
126. e charger face 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on 6 page 6 34 Check charger for proper operation Retractable AC Cord Reel Removal 1 Disconnect retractable AC cord from AC outlet See Onboard Charger Removal on page 6 34 See WARNING on page 6 24 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 6 securing the cord reel housing 2 and its backing plate 3 to vehicle Figure 6 21 Page 6 31 Remove hardware securing U shaped bracket 4 of retractable cord reel assembly 5 5 1 Villager 6 and 8 Remove four screws 6 securing U shaped bracket to charger 5 2 Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transporter 4 and 6 Remove four bolts 7 and locknuts 8 securing U shaped bracket to vehicle 9 Lift retractable cord reel assembly from vehicle Retractable AC Cord Reel Installation 1 2 Install in reverse order of removal Install and tighten U shaped bracket hardware securing retractable cord reel assembly 2 1 Villager 6 and 8 Tighten four screws 6 to 13 in Ib 1 5 N m 2 2 Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transpo
127. e condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages that are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate Monitor the ammeter Under normal operating conditions when the charger is on and the batteries are discharged the charger will shut off in order to run a self diagnostic 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 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 between charges until the bat teries have 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
128. e 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 lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections 2008 Export Battery Charger Maintenance and Service Manual Page 3 7 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL The Charge Circuit ONBOARD t S SOLID STATE COMPUTER FUSE LINK gag SPEED CONTROLLER 1 10 BLACK B TERMINAL CHARGER RECEPTACLE 18 GRAY 3818 GRAY SENSE LEAD FUSE Figure 3 7 Charge Circuit and Battery Configuration Limo Electric Vehicles Page 3 8 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Installation and Operation CHARGER INSTALLATION AND OPERATION See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the ve
129. e 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 charger receptacle onboard computer and batteries Page 3 6 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL KS CHARGER FRONT RECEPTACLE OF VEHICLE LINN ON AS ANO 8L MOV1E OF 95 S SINGLE POSITION CONNECTOR ONBOARD COMPUTER The Charge Circuit 4 BATTERY BANK TO SOLENOID M B SOLID STATE SPEED CONTROLLER Figure 3 6 Charge Circuit and Style C Battery Configuration 6 x 8 Volt Precedent Vehicles LIMO 6 X 8 VOLT The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 7 Page 3 8 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacl
130. e should be less than 2 ohms 3 5 Precedent Verify that the 10 gauge red wire from the charger receptacle is connected to the pos itive post of battery no 1 Figure 3 4 Page 3 5 Figure 3 5 Page 3 6 and Figure 3 6 Page 3 7 4 Check battery pack voltage 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 Figure 3 14 DS DS Villager 4 800 810 and 850 Battery Voltage Test 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 battery no 6 Figure 3 15 Page 3 19 and Figure 3 16 Page 3 19 FRONT EA FRONT OF VEHICLE CAFS OF VEHICLE Figure 3 15 Turf 1 and Carryall 1 Battery Voltage Test Figure 3 16 Limo Battery Voltage Test 2008 Export Battery Charger Maintenance and Service Manual Page 3 19 ES EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures 4 3 Style A and B 4 x 12 Volt Precedent 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 3 17 Page 3 20 or Figure 3 18 Page 3 20 200 DCV SETTING Figure 3 17 Battery Voltage Test Precedent
131. e 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 battery no 1 The DC cord blue wire should be connected to the sense lead fuse The DC cord black wire should be connected to the terminal block located on the vehicle component mounting plate Figure 4 2 Page 4 3 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 4 Onrare occasions both diodes may fail as a result of a lightning strike at the charging location 5 Excessive heat due to a loose connection may also cause both fuse links to blow Be sure fuse connec tions are tightened to 22 in Ib 2 5 N m 6 Ensure that the charger and vehicle are wired properly and all connections are clean and tight 2008 Export Battery Charger Maintenance and Service Manual Page 4 17 EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures TEST PROCEDURE 5 CHARGER DC CIRCUIT CONTINUITY TEST Test Procedure 5A DS Villager 4 See General Warning Section 1 Page 1 1 1 2 3 Disconnect the AC cord from the wall outlet Disconnect the batteries as instructed See General Warning on page 1 1 Disconnect the DC cord blue wire 17 from the 3 way w
132. e wire from the current limiter 15 connected to 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 POSITIVE PIN POSITIVE PIN PULL ERE ey C PUL HERE T a NEGATIVE PIN NEGATIVE PIN Figure 5 13 DC Plug Test Figure 5 14 DC Plug Test Probes Reversed 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 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 An AC circuit test should be done before performing this test procedure to ensure the continuity of the AC cord internal AC circuit breakers and charger wiring See Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 5 17 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 4 To apply AC power directly to the transformer primary coil bypass the relay See step 4 of Charging a Disconnect tran
133. eakers Disconnect the wires marked 2 3 4 and 5 from the voltage selector switch OW dm Go d Place the continuity tester probes on the primary coil transformer wires disconnected above in pairs until all of the combinations in the following chart have been tested 6 Ifthe continuity readings agree with the chart replace the voltage selector switch If the continuity read ings differ from the chart replace the transformer 2008 Export Battery Charger Maintenance and Service Manual Page 5 25 ai EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures PRIMARY COIL CONTINUITY NO CONTINUITY CHART NEGATIVE PROBE 1 2 3 4 5 6 1 Continuity Continuity Sou eset Sa w 2 D Continuity eu Si ene s Continuity Continuity at So PRIN E DORT a SEU Pana Continuity o 2 GERI Soniy ey Continutty Continury d anit Pr Sg Continuity Continuity Secondary Coil 1 Disconnect AC cord from the wall outlet 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 5 15 Page 5 21 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 post with the short black jumper wire 7 Figure 5 20 Page 5 30 Test for continuity between the jumper wire and each of the secondary coil wires tan
134. ectrical service that will be used to power the charger Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING 11 Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Install the charger cover and check charger for proper operation Page 3 32 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Repairs Pa AMMETER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Ammeter 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 Using two wrenches to prevent the posts from turning disconnect the DC cord black wire 5 and buss bar 3 from the ammeter Figure 3 29 Page 3 33 4 Remove the two nuts 2 that secure the ammeter to the charger face 5 Remove the ammeter from the face of the charger Figure 3 29 Ammeter Ammeter Installation 1 Place the ammeter in position in the charger face Figure 3 29 Page 3 33 Install the nuts 2 and tighten until ammeter is firmly secured Connect the DC cord black wire 5 to the left as viewed from inside the charger post of the ammeter PON Connect the buss bar 3 from the fuse link to the right post of the a
135. ed 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 2008 Export Battery Charger Maintenance and Service Manual Page 6 5 E EXPORT IQ PLUS CHARGER ONBOARD Onboard Charger Operation each night in order to avoid deep discharging the batteries use the CDM Communication Display Module CCI P N 101831801 See Communication Display Module in the appropriate main tenance and service supplement TESTING CHARGER OPERATION 1 Connect the AC power supply cord to an electrical outlet The charger relay should not close immedi ately but should close with an audible click after a delay of 2 to 15 seconds See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted and the batteries are less than 9096 charged 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 DC CORDSET DIODES WITH HEATSINK t BLACK FUSE AMMETER I SECONDARY COIL CONTROL PRIMARY BOARD Coll TRANSFORMER AC CORD WHITE or BLUE BLACK or BROWN GR
136. ediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 1 With the charger DC cord disconnected from the vehicle charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 3 8 Page 3 10 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected See following WARNING 2008 Export Battery Charger Maintenance and Service Manual Page 3 11 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Installation and Operation A WARNING Do not rock or bend the DC 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 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon th
137. ee General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 To check the diodes use Test Procedure 4A Single Diode Failure on page 5 18 If both diodes have failed closed both charger fuse links 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 Figure 5 2 Page 5 3 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 connected to the limiter which connects to the relay coil and the DC cord black wire should be connected to the left side of the ammeter when viewed from inside the charger Figure 5 6 Page 5 9 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 On rare occasions both diodes may fail as a result of a lightning strike at the charging location 4 Excessive heat due to a loose connection may also cause both fuse links to blow Be sure fuse connec tio
138. emove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Place heatsink against charger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts that secure the heatsink to the case Tighten the bolts to 22 in Ib 2 5 N m Figure 3 11 Page 3 13 and Figure 3 12 Page 3 17 2 Connectthe red wire from the DC cord and the red wire from the charger relay to the center terminal post on the heatsink Tighten nut to 18 in Ib 2 0 N m 3 Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 4 Connect the other secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 5 Install the charger cover and check charger for proper operation 2008 Export Battery Charger Maintenance and Service Manual Page 3 31 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Repairs TRANSFORMER See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Transformer 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 Note the locations of wire ties and remove the wire ties 4 Disconnect the black primary coil leads from the AC circuit breakers and the voltage selector switch Figure 3 11 Page 3 13 an
139. enance and Service Manual Page 3 35 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Repairs CHARGER AC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 AC Cord Removal 1 akon Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 3 30 Remove the charger cover Disconnect the brown wire from the AC cord from terminal 6 at the relay Figure 3 11 Page 3 13 Disconnect the blue wire from the AC cord from terminal 4 at the relay Figure 3 11 Page 3 13 Disconnect the AC cord green yellow wire at the charger base Figure 3 11 Page 3 13 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 Connect the brown wire to terminal 6 at the charger relay the blue wire to terminal 4 at the charger relay and the green yellow wire to the charger base Tighten the screw on the green yellow wire terminal to 18 in Ib 2 0 N m Figure 3 11 Page 3 13 Position the strain relief bushing on the AC cord 4 Using pliers install the strain relief bushing and AC cord into the mounting hole in the charger face 5 Install the charger cover Page 3 36 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY
140. energy units of discharge or 36 holes of golf between charges until the batteries have 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 in Section 11 of the appropriate mainte nance and service manual TESTING CHARGER OPERATION 1 Connect the AC power supply cord to an electrical outlet The charger relay should not close immedi ately but should close with an audible click after a delay of 2 to 15 seconds See following NOTE NOTE Monitor the charge cycle to make sure the charger turns off properly If the charge cycle is inter rupted and the batteries are less than 9096 charged the battery warning light will illuminate inter mittently See Battery Warning Light on page 4 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 4 2 Page 4 3 and that the internal charger wiring is correct Figure 4 5 Page 4 7 Page 4 6 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD DC CORDSET CONTROL BOARD END AC CORD WHITE or BLUE BL
141. ense 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 All vehicles except Precedent Repeated failure of sense lead fuses is a symptom of a voltage supressor that has failed in a closed condition Precedent vehicles only Failure of the onboard computer due to a blown internal sense lead fuse is a symptom of a voltage supressor that has failed in a closed condition Relay 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove the brown wire from terminal 6 of the relay and black wire from terminal 9 of the relay Figure 3 11 Page 3 13 Place continuity tester leads on terminals 6 and 9 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 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 and the relay must be replaced 5 With batteries connected insert the DC plug into a receptacle The tester s
142. eplaced Page 6 14 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Test Procedures 6 7 On rare occasions a single fuse link may blow due to excessive heat This can be caused by a loose internal fuse connection Check all three fuse connections inside the charger to be sure they are clean and tight The proper tightness for the fuse link connections is 22 in Ib 2 5 N m 8 Ensure that the charger is wired properly and all connections are clean and tight See following CAU TION CAUTION f connections are not clean and tight excessive heat will be created and the charger may become damaged DISCONNECTED SECONDARY COIL WIRE Figure 6 10 Diode Test Figure 6 11 Diode Test Probes Reversed Test Procedure 4B Both Diodes Failed See General Warning Section 1 Page 1 1 To check the diodes use Test Procedure 4A Single Diode Failure on page 6 14 If both diodes have failed closed both charger fuse links 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 breaker 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 Figure 6 2 Page 6 3 2 Make sure the charger
143. eptacle the onboard computer locks out the vehi cle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge IQ Plus vehicles with IQ Plus chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service unplug the charger DC cord wait 15 seconds for the computer to reset and plug the charger back in See following WARNING Allow the vehicle to com plete one full charge cycle before putting it into service This will ensure the batteries are at their opti mum charge prior to returning the vehicle to service A WARNING The charger plug must be pulled slowly from the receptacle Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode BATTERY WARNING LIGHT 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 disconnected 2 AC power to charger is interru
144. er to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 1 With the charger DC cord disconnected from the vehicle charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 5 4 Page 5 7 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected See following WARNING Page 5 6 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL External Charger Installation and Operation EJ A WARNING Do not rock or bend the DC plug To connect the charger plug
145. eriodic 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 2008 Export Battery Charger Maintenance and Service Manual Page i A WARNING e 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 w
146. erse order Figure 1 7 Transporter 4 and 6 and Carryall 6 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 2008 Export Battery Charger Maintenance and Service Manual Figure 1 6 Turf 2 and 252 Carryall 2 and 252 XRT 900 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 Figure 1 8 Villager 6 and 8 IQ Plus Battery Configuration Viewed from driver side of vehicle 1 Place TOW RUN Switch in TO connecting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order before disconnecting or Page 1 5 SAFETY General Warning Figure 1 9 Limo Manual Brake Battery Configuration Figure 1 10 Limo AutoBrake Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or 1 Place TOW STORAGE RUN Switch in STORAGE before connecting battery cables disconnecting or connecting battery cables 2 Remove negative battery cable 2 Remove negative battery cable
147. erty damage severe personal injury or death 9 Install the charger cover and the retaining screws 10 Plug the 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 determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual PH DC CORDSET is DIODES WITH r HEATSINK HH CK FUSE AMMETER RELAY BYPASS RELAY BYPASS SECONDARY JUMPER WIRE JUMPER WIRE COIL PRIMARY COIL TRANSFORMER BLUE GRN YEL AC CIRCUIT BREAKERS BLACK TAN 6 A BLACK BLACK TERMINAL AC VOLTAGE SELECTOR SWITCH BLACK 6 Figure 3 31 Export PowerDrive Charger Wiring Diagram Relay Bypassed Page 3 38 2008 Export Battery Charger Maintenance and Service Manual SECTION 4 EXPORT POWERDRIVE CHARGER ONBOARD A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 GENERAL INFORMATION This section includes information pertaining to service of the Export onboard PowerDrive battery charger Model number 17790 10 is use
148. ery 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 Figure 4 25 Ammeter Ammeter Installation 1 Place the ammeter in position in the charger face Figure 4 25 Page 4 29 Install nuts 2 and tighten until ammeter is firmly secured Connect the DC cord black wire 5 to the left as viewed from inside the charger post of the ammeter ON 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 2008 Export Battery Charger Maintenance and Service Manual Page 4 29 EXPORT POWERDRIVE CHARGER ONBOARD Charger Repairs 5 Thread nuts 4 onto both posts of ammeter until just past finger tight While holding the inside nut tighten the outside nut 4 1 4 turn See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 6 Install charger cover and install charger in vehicle See Onboard Charger Installation on page 4 36 7 Check charger for proper operation FUSE LINK See General Warning Section 1 Page
149. es 4x 12 Volt Batteries Viewed from driver side of vehicle Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables connecting battery cables 2 Remove negative battery cable 2 Remove negative battery cable 3 Remove positive battery cable 3 Remove positive battery cable Connect battery cables in reverse order Connect battery cables in reverse order Figure 1 3 Precedent Battery Configuration Style C Figure 1 4 DS DS Villager 4 800 810 and 850 12 Volt 6 x 8 Volt Batteries Battery Configuration Viewed from driver side of vehicle Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables connecting battery cables 2 Remove negative battery cable 2 Remove negative battery cable 3 Remove positive battery cable 3 Remove positive battery cable Connect battery cables in reverse order Connect battery cables in reverse order Page 1 4 2008 Export Battery Charger Maintenance and Service Manual SAFETY General Warning Figure 1 5 Turf1 and Carryall 1 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 rev
150. esentative to obtain the proper cord or plug Connect the power supply cord to an AC supply within the acceptable voltage range See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with all applica ble national and local electrical codes and regulations Place the charger AC cord so it will not be stepped on tripped over or otherwise subject to damage or stress The use of an extension cord with the onboard charger must be avoided Do not place items in the compartment where the battery charger is installed Ensure that the charger venti lation slots are unobstructed Page 6 4 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Onboard Charger Operation 6 AC INPUT VOLTAGE SELECTION SWITCH REAR CHARGER PANEL Figure 6 3 AC Input Voltage Selection Switch CHARGING BATTERIES 1 Connect the AC power supply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 The charger will activate automatically within 2 to 15 seconds 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the cond
151. est Procedure 4 Diodes on page 3 22 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 3 26 6 Remove the DC cord blue wire from the red wire connected to the charger relay and check continuity between 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 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 An AC circuit test should be done before performing this test procedure to ensure the continuity of the AC cord internal AC circuit breakers and charger wiring See Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 21 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect transformer secondary coil wires from the heatsink Figure 3 25 Page 3 25 4 To apply AC power directly to the transformer primary coil bypass the relay See Charging a Bat
152. est for continuity on each of the flat blades and on the round pin of the AC plug The tester should indicate continuity on the ground pin only If any other reading is obtained the AC cord has failed and must be replaced Figure 5 17 AC Cord Test 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 2008 Export Battery Charger Maintenance and Service Manual Page 5 23 Is EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures 3 Disconnect green yellow wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 5 18 Page 5 24 4 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire removed from relay terminal 4 4 Figure 5 18 Page 5 24 Test for continuity on the appropriate pin of the AC charger receptacle on front of charger The tester should indicate continuity on the ground pin only If any other reading is obtained the AC charger receptacle or connecting wires have failed and must be replaced 5 Put the red probe on the end of the green yellow wire 2 and with the black probe check for con tinuity on the appropriate pin of the AC charger receptacle Figure 5 18 Page 5 24 and Figure 5 6
153. evere 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 2008 Export Battery Charger Maintenance and Service Manual Page 1 1 SAFETY General Warning A 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 cha
154. g 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 1 Turn key switch OFF and place the Forward Reverse handle in the NEUTRAL position Leave the bat teries connected 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 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 2 on the relay Disconnect the black wire from the relay terminal Figure 5 22 Page 5 35 4 2 Disconnect the black wire from relay terminal 4 4 3 Use ajumper 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 ajumper wire with alligator clips to connect the black wire from relay terminal 6 to the black wire from relay terminal 8 Figure 5 22 Page 5 35 See following DANGER A 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 5 Plug the DC cord into the charger receptacle first the
155. g 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 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 voltage for your area have building wiring checked by a licensed electrical contractor SETTING ON AC VOLTAGE MINIMUM AC VOLTAGE MAXIMUM AC VOLTAGE SELECTOR SWITCH PERMITTED PERMITTED 100 Volts AC 95 105 200 Volts AC 190 210 220 Volts AC 209 231 240 Volts AC 228 252 5 Check continuity of the AC circuit 5 1 Remove the charger cover 5 2 Bypass the relay See step 4 of Charging a Battery Pack that has Low Voltage on page 5 34 5 3 With relay bypassed there should be continuity across the AC cord blades Figure 5 10 Page 5 18 2008 Export Battery Charger Maintenance and Service Manual Page 5 17 Is EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures AC plug may have different appearance depending on geographic region 6 Figure 5 10 AC Cord Test If the circuit is not complete check the wiring of the AC cord 16 or 17 AC charger receptacle 14 trans former primary coil wires 21 internal AC circuit breakers 13 voltage selector s
156. geographic region the charger provided with your vehicle may be a different model Do not attempt to service a battery charger that has not been prop erly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor For battery chargers with model numbers listed above that are installed in vehicles other than IQ Plus vehi cles contact your local Club Car dealer or distributor The IQ Plus battery charger is automatic and has no external controls Figure 6 1 Page 6 1 When the AC cord is plugged in there is a 2 to 15 second delay before charging begins See following NOTE NOTE At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer OBC records the amount of energy consumed as the vehicle is used then directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging Figure 6 1 Onboard IQ Plus Battery Charger 2008 Export Battery Charger Maintenance and Service Manual Page 6 1 6 EXPORT IQ PLUS CHARGER ONBOARD The Charge Circuit IQ PLUS ONBOARD CHARGER FEATURES Charge Interlock When the AC power cord is inserted into a wall receptacle the
157. ger from the vehicle See Onboard Charger Removal on page 4 35 Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not use a battery charger if the cord or plug 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 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 in an electrical shock Do not use an adapter to plug charger into a two blade outlet or an extension cord AC outlet must accept grounded three blade plug The use of an extension cord could result in fire or electric shock Do not operate 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 Chargers can ignite flammable materials and vapors Do not use near fuels grain dust solvents thinner or other flammables Keep
158. ger 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 and connections between the charger receptacle onboard computer and batteries TO SOLENOID d CHARGER OF VEHICLE SN e NS SN BATTERY BANK AVHD 8Lit Movi18 OL SINGLE POSITION CONNECTOR ONBOARD 5 COMPUTER Figure 3 4 Charge Circuit and Style A Battery Configuration 4 x 12 Volt Precedent Vehicles 2008 Export Battery Charger Maintenance and Service Manual Page 3 5 Fa EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL The Charge Circuit CHARGER RECEPTACLE Q J z COMPUTER j F CONTROLLER Figure 3 5 Charge Circuit and Style B Battery Configuration 4 x 12 Volt Precedent Vehicles PRECEDENT 6 X 8 VOLT The vehicle charge circuit consists of the following components charger receptacle onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 6 Page 3 7 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 Th
159. ger relay will have to be bypassed to activate the charger 1 Turn key switch OFF and place the Forward Reverse switch in the NEUTRAL position 2 Disconnect the AC and DC cords and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 See WARNING on page 4 26 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 4 27 Page 4 34 4 2 Disconnect the black wire from relay terminal 6 4 3 Usea 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 Usea jumper wire with alligator clips to connect the black wire from relay terminal 7 to the black wire from relay terminal 4 Figure 4 27 Page 4 34 See following DANGER A 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 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 4 36 6 Plug the AC cord into an electrical outlet The charger should activate
160. he use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Be sure the fuse link is clean and tight not applicable to Precedent vehicles Be sure all wire connections at the 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 straight out of the receptacle Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person imm
161. heatsink and tighten the nut to 18 in Ib 2 0 N m 3 Attach the blue wire of new DC cord to the limiter 15 Figure 5 19 Page 5 25 4 Attach the black wire 17 of the new DC cord to ammeter Install nut onto post of ammeter slightly more than finger tight While holding the inside nut tighten the outside nut 1 4 turn See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Using pliers put the strain relief bushing 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 A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 8 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 1 2 N m HEATSINK See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Heatsink 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 Remove both secondary coil transformer wires tan from the heatsink Figure 5 6 Page 5 9 and Figure 5 7
162. hicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle The battery charger DC plug must be pulled slowly from the receptacle Figure 3 8 Page 3 10 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 3 9 Page 3 10 Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use Each charger should have its own branch circuit protection circuit breaker or fuse rated in accordance with applicable national electrical codes and regulations Improper AC supply circuit p
163. hould indicate continuity on terminals 6 and 9 and continuity on relay terminals 4 and 7 If tester does not indicate continuity on both sets of contacts the relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Disconnect the black wire from the left ammeter post as viewed from inside the charger 4 Place the continuity tester clip on one of the ammeter posts 5 Place the continuity test probe on the other ammeter post The tester should indicate continuity If the tester does not indicate continuity replace the ammeter AC Circuit Breaker PF ON Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the wires from the AC circuit breaker 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 continuity replace the AC circuit breaker 2008 Export Battery Charger Maintenance and Service Manual Page 3 29 a EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Repairs CHARGER REPAIRS See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 3 11 Page 3 13 Prior to servicing the charger disconnect the AC power supply cord f
164. hten nut to 18 in Ib 2 0 N m 5 Install charger cover and install charger in vehicle See Onboard Charger Installation on page 4 36 6 Check charger for proper operation TRANSFORMER See General Warning Section 1 Page 1 1 Transformer Removal 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 4 35 See WARNING on page 4 26 2 Remove the charger cover 3 Note the locations of wire ties and remove the wire ties 4 Disconnect the black primary coil leads from the AC circuit breakers and the voltage selector switch Figure 4 26 Page 4 31 and Figure 4 27 Page 4 34 5 Disconnect the two tan secondary coil transformer wires from heatsink Figure 4 18 Page 4 20 6 Disconnect the two black secondary coil transformer wires from the 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 Ib 3 2 N m Connect one secondary coil transformer wire black to one terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Figure 4 5 Page 4 7 Connect the other secondary coil transformer wire black to the remaining terminal of the fuse Tighten nut to 22 in Ib 2 5 N m Connect one secondary coil transformer wire tan to the
165. ical system to determine which electrical component has failed See Section 11 Electrical System and Testing in the appropriate maintenance and service manual DC CORDSET DIODES WITH HEATSINK D E z z E aD B FUSE E SECONDARY COIL IL TU I CONTROL PRIMARY BOARD J COIL AMMETER TRANSFORMER BLACK GREEN or GREENYELLOW RELAY BYPASS RELAY BYPASS JUMPER WIRE JUMPER WIRE CASE GROUND BLACK BLACK TAN 1 Kn AC CIRCUIT BREAKERS TERMINAL BLACK TAN 6 AC VOLTAGE SELECTOR SWITCH Figure 4 27 PowerDrive Onboard Charger Wiring Diagram Relay Bypassed Page 4 34 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Onboard Charger Removal and Installation ONBOARD CHARGER REMOVAL AND INSTALLATION See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 5 Page 4 7 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 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 fr
166. icient current See Section 2 Charger Identification and Specifica tions 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 3 10 Page 3 10 See following CAUTION and NOTE 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 with your charger has the proper AC plug for your location If it does not contact your Club Car representative to obtain the proper cord or plug AC INPUT VOLTAGE SELECTION SWITCH REAR CHARGER PANEL Figure 3 10 AC Input Voltage Selection Switch Page 3 10 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Installation and Operation With charger DC cord disconnected connect the power supply cord to an AC supply within the acceptable voltage range See Battery Charger Specifications Section 2 Page 2 1 To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with all applica ble national and local electrical codes and regulations T
167. ide nut 1 4 turn See following CAUTION Page 5 30 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Charger Repairs a CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Install the charger cover 6 Plug the charger into the vehicle and check ammeter for proper operation FUSE LINK See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Fuse Link Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 Remove both black secondary coil transformer wires and the black jumper wire 18 from the back of the fuse link assembly 11 Figure 5 7 Page 5 13 4 Remove screws from the front of the charger and remove the fuse link assembly Fuse Link Installation 1 Place clear plastic cover over fuse assembly 11 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 jumper wire 18 over the center branch of the fuse assembly and ammeter post Figure 5 7 Page 5 13 Tighten to 22 in Ib 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 rema
168. ie e oed ed eda e hat EUR 4 31 Charger AC Cord and Retractable Cord Reel ssssssssssseeeeeenne eene 4 32 Charging a Battery Pack that has Low Voltage sse eme 4 33 Onboard Charger Removal and Installation ssseeenem mem 4 35 DS Villager E 4 35 Precedent Velicles 1 cote nett Min R isan idc p pecE m ap beiden Mr aa indt 4 36 Page iv 2008 Export Battery Charger Maintenance and Service Manual SECTION 5 EXPORT IQ PLUS CHARGER EXTERNAL General Iriformatior 3 e et etit ua inspect ed tique tia tecti EEE EEEE aAa 5 1 IQ Plus External Charger Features sssssssessseseeeen eee eene eren nennen nennen 5 2 Battery Warning Light eiecit eerte ertt edd tud dde id edd ted edd d enu d S 5 2 The Charge Circuit 5 aise cans tre tee dette deti teo ade tr td aet A 5 3 External Charger Installation and Operation ssssse enne 5 4 AG Power Connection anesediii tiii eee dide eddie sedie dae uenia ded eed edad 5 5 Charging Batteries 4 inedite ete coves Lee ed edv Lee dede eee dees ev eerte d dede v e edd Ed 5 6 External Charger Plug and Receptacle ssssssssseee enne eene 5 8 Checking Battery Condition with an External Charger ssssssse ee 5 8 Start Charge Cycle dabit ena np deuten ame bah abs 5 8 Testing Charger Operation 2 e cO E o REOR BRE RE EMI RR E D
169. in accordance with all applica ble national and local electrical codes and regulations The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation 2008 Export Battery Charger Maintenance and Service Manual Page 5 5 E EXPORT IQ PLUS CHARGER EXTERNAL External Charger Installation and Operation AC INPUT VOLTAGE SELECTION SWITCH Figure 5 3 AC Input Voltage Selection Switch CHARGING BATTERIES A WARNING Do not bypass the sense lead fuse Be sure the fuse link is clean and tight Be sure all wire connections at the 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 5 4 Do not pull on the DC cord Figure 5 5 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 straight out of the receptacle Do not connect a charg
170. in the appropriate maintenance and service manual TEST PROCEDURE 8 CONTINUITY See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 AC Cord and Battery Charger AC Receptacle 1 2 3 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the green yellow wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 5 16 Page 5 23 4 Disconnect black wire of AC receptacle from charger relay terminal 4 5 Disconnect other black wire of AC receptacle from the charger relay terminal 8 6 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire removed from relay terminal 4 4 Test for continuity 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 Place the red probe on the end of the green yellow wire 2 and with the black probe check for con tinuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only the ground pin 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 a
171. ining termi nal Tighten to 27 in Ib 3 0 N m 4 Install the charger cover VOLTAGE SUPPRESSOR See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 The voltage suppressor which is incorporated into a wire assembly in the charger protects the onboard com puter by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehicle See also Test Procedure 8 Conti nuity on page 5 22 Voltage Suppressor Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Remove nut attaching voltage suppressor 18 gauge red wire 2 to heatsink Figure 5 21 Page 5 32 Disconnect the limiter 4 at the quick disconnect terminal on the relay side Disconnect the voltage suppressor wire assembly from charger relay 3 ogg F wo DN Remove the white fiberglass sleeve from the red heatsink wire Retain the sleeve for use when installing the new voltage suppressor 2008 Export Battery Charger Maintenance and Service Manual Page 5 31 IE EXPORT IQ PLUS CHARGER EXTERNAL Charger Repairs Voltage Suppressor Installation 1 Place the white fiberglass sleeve over the red wire that connects to the heatsink 2 Install in reverse order of removal Tighten nut attaching voltage suppressor 18 gauge red wire to heat sink to 18 in Ib 2 0 N m Figu
172. ions are tightened to 22 in Ib 2 5 N m Ensure that the charger and vehicle are wired properly and all connections are clean and tight TEST PROCEDURE 5 CHARGER DC CIRCUIT CONTINUITY TEST See General Warning Section 1 Page 1 1 1 Disconnect the AC cord from the wall outlet 2 Disconnect the batteries as instructed See General Warning Section 1 Page 1 1 3 4 Using a continuity tester CCI P N 1011273 or multimeter set to 200 ohms connect the test probes to Disconnect the charger DC cord at the three pin connector 8 Figure 6 23 Page 6 35 the charger DC cord black wire and red wire terminals in the three pin connector Note the reading Reverse the test probes and check the DC cord again The circuit should show continuity in only one direction 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 6 18 Also check the diodes heatsink See Test Procedure 4 Diodes on page 6 14 If the circuit shows continuity in both directions a short circuit exists in the charger DC circuit usually caused 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 Check continuity between the DC cord red black and blue wires Figure 6 4 P
173. ire adapter 18 at the sense lead fuse 20 Figure 4 29 Page 4 36 4 Disconnect the DC cord red wire from the positive post of battery no 1 5 Disconnect the DC cord black wire 19 from the charger receptacle fuse link Figure 4 29 Page 4 36 6 Using a continuity tester CCI P N 1011273 or multimeter set to 200 ohms connect the test probes to 10 the DC cord black wire and the DC cord red wire Figure 4 16 Page 4 18 Note the reading Reverse the test probes and check the DC cord again Figure 4 17 Page 4 18 The circuit should show continuity in only one direction 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 4 Diodes on page 4 16 If the circuit shows continuity in both directions a short circuit exists in the charger DC circuit usually caused by failed diodes See Test Procedure 4 Diodes on page 4 16 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 4 21 Remove the DC cord blue wire from the control board and check continuity between the DC cord red black and blue wires Figure 4 5 Page 4 7 There should be no continuity X BLUE WIRE N BLACK WIRE A BLACK WIRE Figure 4 16 DC Cord Test DS Villager 4 Fig
174. ire from terminal 2 of the relay and black wire from terminal 4 of the relay Figure 5 6 Page 5 9 Place continuity tester leads on terminals 2 and 4 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 With batteries connected insert the DC plug into a receptacle The tester should indicate continuity on terminals 6 and 8 and continuity on relay terminals 2 and 4 If tester does not indicate continuity on both sets of contacts the relay must be replaced Ammeter 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Remove the charger cover Disconnect the black wire from the left ammeter post as viewed from inside the charger Place the continuity tester clip on one of the ammeter posts gi d cow Place the continuity test probe on the other ammeter post The tester should indicate continuity If 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 Remove the charger cover Disconnect the wires from the AC circuit breaker P 0O N 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 continuity replace the AC circuit breaker CHARGER REPAIRS See General Warning Section 1 Page 1 1 Se
175. 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 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 solenoid post as the 6 gauge red wire connected to the positive post of battery no 1 The DC cord blue wire should be connected to the sense lead fuse The DC cord black wire should be con nected to the terminal block located on the vehicle component mounting plate Figure 6 2 Page 6 3 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 4 On rare occasions both diodes may fail as a result of a lightning strike at the charging location 2008 Export Battery Charger Maintenance and Service Manual Page 6 15 ES EXPORT IQ PLUS CHARGER ONBOARD Test Procedures 5 6 Excessive heat due to a loose connection may also cause both fuse links to blow Be sure fuse connec t
176. it Check the connections between the 18 gauge gray wire from the charger recep tacle the sense lead fuse and the 18 gauge gray wire from the onboard computer In addition check the charger receptacle fuse link and its connections ONBOARD pw SOLID STATE COMPUTER SPEED CONTROLLER FUSE LINK e 10 BLACK C a 6 BLACK TN 7 M N CHARGER HOBLACK c RECEPTACLE N 10 BLACK 18 GRAY 10 RED SENSE LEAD FUSE Figure 3 2 Charge Circuit and Battery Configuration DS DS Villager 4 800 810 and 850 2008 Export Battery Charger Maintenance and Service Manual Page 3 3 EH EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL The Charge Circuit TURF 1 AND CARRYALL 1 The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 3 Page 3 4 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 6 The positive terminal of the charger receptacle is connected to the 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
177. ithout 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 PO Box 204658 Augusta GA 30917 4658 USA Attention Warranty Administration Page ii 2008 Export Battery Charger Maintenance and Service Manual CONTENTS SECTION 1 SAFETY Generel Waung ERR 1 1 SECTION 2 CHARGER IDENTIFICATION AND SPECIFICATIONS General lrformatiorn a terrm rr ita nlt a t fite elk ees EE S 2 1 Battery Charger Specifications nemcina dinani rai EE nennen nnne enne 2 1 Battery Charger Identification naini eaen aE EE A EAE EEE E AAEE EEEREN EARR 2 6 SECTION 3 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL General InfOrrriatiOl uerit erred htt eem et eed dae aa AAE A Eae Gages PRA ee CREBRA RUE ERE aed 3 1 PowerDrive Charger Features cccceccccscceceeeseeeeeseeseeeseseeenenseeceaneneeeeenseeeaaeenaneeaeeeeenneecaecetennaees 3 2 Battery Warning Light icit e oe ete tiere tete deri tnter eade dde ped ana ree Eae ined 3 2 HSenrmeael dee 3 3 DS DS Villager 4 800 810 and 850 ssssssssssssssssssseeeeee ener enne 3 3 T r Tand Carryall T E 3 4 Precedent 4 x 12 Volt eese er eere edente ned tie d E A tds 3 5 Precedent 6 x 8 Volt ise ede eterne thea e dn th deed deti EA ded nid d d nin 3 6 H
178. ition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 Monitor the ammeter for about 30 seconds Under normal operating conditions when the charger is on and the batteries are discharged one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero See following CAUTION and NOTE A CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage 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 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 between charges until the bat teries have been properly season
179. leshooting the export IQ Plus onboard battery charger model number 25660 40 The Troubleshooting Guide encompasses the entire battery charging circuit Test procedures specified in the Troubleshooting Guide can be found on the following pages 2008 Export Battery Charger Maintenance and Service Manual Page 6 7 6 EXPORT IQ PLUS CHARGER ONBOARD Troubleshooting IQ PLUS ONBOARD BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay does not close no transformer Batteries disconnected Connect batteries Figure 6 5 Page 6 11 hum and ammeter does not move Battery voltage is too low Test Procedure 1 Battery Voltage on page 6 10 Improper vehicle or battery charger wiring See Figure 6 2 Page 6 3 Figure 6 4 Page 6 6 and Figure 6 5 Page 6 11 DC circuit Test Procedure 5 Charger DC Circuit Continuity Test on page 6 16 Onboard computer malfunction Test Procedure 2 Control Board on page 6 12 Gray sense lead fuse is blown Test Procedure 1 Battery Voltage on page 6 10 Control board malfunction Test Procedure 2 Control Board on page 6 12 Relay closes with an audible 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 6 13 Failed AC plug and cord Test Procedure 3 AC Power and Continuity Check of
180. lete 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 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the opera tor that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals 25 seconds at 10 second intervals for Precedent vehicles if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer THE CHARGE CIRCUIT For vehicles with onboard chargers the charge circuit consists of the following components onboard charger onboard computer batteries DS Villager 4 The black wire from the charger is connected to the fuse link along with the short black receptacle wire on the charger receptacle Figure 4 2 Page 4 3 One 10 gauge black wire from the onboard computer con nects to other side of the charger receptacle fuse link The other 10 gauge black wire from the onboard com puter connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and
181. lso AC Charger Receptacle on page 5 23 Place the red probe on the blue wire and check for continuity on both flat blades and on the ground pin of the AC plug The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord and plug must be replaced AC Cord Disconnect the AC cord from the AC receptacle on front of battery charger and the incoming AC outlet Using a multimeter set for 200 ohms place the red probe into one of the side terminals in the end of the AC cord as shown Figure 5 17 Page 5 23 Test for continuity on each of the flat blades and on the round pin of the AC plug The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord has failed and must be replaced Using a multimeter set for 200 ohms place the red probe into the other side terminal in the end of the AC cord Test for continuity on each of the flat blades and on the round pin of the AC plug The tester should indicate continuity on only one flat blade If any other reading is obtained the AC cord has failed and must be replaced Page 5 22 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures EX nt LLLI Figure 5 16 AC Plug and AC Charger Receptacle Continuity Test 4 Using a multimeter set for 200 ohms place the red probe into the center terminal in the end of the AC cord T
182. mmeter Place flat washers on both sides of the buss bar 5 Thread nuts 4 onto both posts of the ammeter until just past finger tight While holding the inside nut tighten the outside nut 1 4 turn See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 6 Install the charger cover 7 Plug the charger into the vehicle and check ammeter for proper operation 2008 Export Battery Charger Maintenance and Service Manual Page 3 33 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Repairs FUSE LINK See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 Fuse Link 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 black secondary coil transformer wires and the buss bar 3 from the back of the fuse link assembly Figure 3 29 Page 3 33 4 Remove screws from the front of the charger and remove the fuse 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 3 29 Page 3 33 Tighten to 22 in Ib 2 5
183. mo 6568 Volt sitet dien cce d On tn uota te sa gte adensted daeriene ads sarees 3 7 Charger Installation and Operation sssssssseeeenneemeneeemenenen nennen nnne 3 9 AC Power Connection ueniet eL b pe ERE ed et E 3 10 Charging Batteries 0 iro ee RU aU Vete ep cemere 3 11 Testing Charger Operation xi e i e t eet T uc e ed P EO ed aad 3 12 DC Gord and Plug Inspection eee eed e ate erede n Es 3 12 Checking Battery Condition After a Charge Cycle ssssssssseeee eene 3 14 Start Charge Cycle dics cette idee dci mede ie dede ne dau de dava n d dv Rede a 3 14 Troubleshooting meenet P 3 14 Test PIOCOGUFres inaia uide EEE EE E EE AERE 3 18 Index of Test ProCedures t EH RED ERE d Ree ER E diee c Lo Ea pad 3 18 2008 Export Battery Charger Maintenance and Service Manual Page iii Bjeuer mmm 3 30 niri dme a 3 31 Tiranstormef 4 3 e ae enn te itg ae icut te p E tei aedes 3 32 ume Em 3 33 Buse Linke deti tei eiie i ed e eleg iad Hc ll tibl di dta aer an 3 34 Voltage SuppresSsor e tite etr odere tel atl ba ret Bea octo bl tao adt ade ea aaisa 3 34 Charger Relay c ou ee EM Ucet EE Re del Heo red a Ee Hoe ee MU Ue EE EE E ete oe boe tug 3 35 Charger AC Circuit Breakers cccceseccceceeeseeneeteeseeeeeseeesaneeeeeeaueeeeceesuanseeseegeeneeseeeeseeneeteeneneeees 3 35 Charger AG CON ins 2 enn rte ede tu tute
184. n of the AC plug The tester should indicate continuity on only the round pin If any other reading is obtained the retractable cord reel must be replaced 8 If the correct readings are obtained in all of the previous steps the retractable cord reel is functioning properly DC Cord 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 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 other end of the DC cord The tester should indicate continuity on the red DC cord wire only If any other reading is obtained the DC cord must be replaced 7 Place the red probe on the blue 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 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
185. n plug the AC cord into an electrical outlet 6 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING Do not leave the vehicle unattended while it is charging A charger operating with a bypassed relay could short circuit and possibly cause a fire 7 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 8 Disconnect the jumper wires from the relay wires and connect each wire to the original terminal on the relay Figure 5 22 Page 5 35 See following WARNING Page 5 34 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Charging a Battery Pack that has Low Voltage EJ HEATSINK T SUBE SATEH ASSEMBLY ASSEMBLY _ W DIODES SLIDE SWITCH POSITION SECONDARY ER FUSE p ASSEMBLY I TRANSFORME m x PRIMARY amp AMMETER BLACK RELAY BYPASS ERE RELAY BYPASS JUMPER WIRE RE OUPUT r BLACK ey ORDSET EG BUSHING OUTPUT POLARITY RED 4 POS TOP oUTPUT BLACK NEG CIRCUIT cORDsET BLUE COMMUNICATION BREAKER BLACK MT RS a SUPPRESSOR Cee I GREEN YELLOW
186. n practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With the PowerDrive battery charger this practice is not necessary The onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the cen ter dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart See Trouble shooting on page 3 14 If the specified test procedures identify no problems plug the DC cord into the vehi cle and let it charge until the charger shuts off automatically If a problem is found correct it and charge the vehicle Normal battery voltage near the end of a charge cycle 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 are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TROUBLESHOOTING See General Warning Section 1 Page 1 1 See a
187. n 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 than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer THE CHARGE CIRCUIT For vehicles with onboard chargers the charge circuit consists of the following components onboard charger onboard computer batteries The 10 gauge black wire from the charger connects to the onboard computer black lead wire The 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the neg ative post of battery no 8 Figure 6 5 Page 6 11 The 10 gauge red wire of the charger is connected to the positive post of battery no 1 for Turf 2 252 Carryall 2 252 and XRT 900 vehicles and the large post of the solenoid battery side for Carryall 6 Villager and TransPorter vehicles The 18 gauge gray wire from the charger connects to the onboard computer Figure 6 2 Page 6 3 Page 6 2 2008 Export Battery Charge
188. ne flat blade If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 10 Ifthe correct readings are obtained in all of the previous steps the short AC cord and the retractable cord reel are functioning properly If any of the readings are incorrect proceed to the following test procedures to determine which of the two components has failed Short AC Cord without Retractable Cord Reel Check continuity of the short AC cord without the retractable cord reel 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 Disconnect the short AC cord from the retractable cord reel Remove the charger cover Disconnect the black or brown wire 1 of AC cord from the control board NO a R Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black or brown wire 1 Test for continuity on each of the flat blades and then 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 short AC cord must be replaced Disconnect the green or green yellow wire 2 from charger case and position it so it does not touch any metal part of
189. ng 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 Never push objects of any kind into the battery charger case through the ventilation slots Failure to heed this warning could result in an electrical short circuit that could result in a fire Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not use a battery charger if it has received a sharp blow was dropped or was otherwise damaged Make sure it is operating properly before putting it back in use WARNING CONTINUED ON NEXT PAGE Page 1 2 2008 Export Battery Charger Maintenance and Service Manual SAFETY General Warning A WARNING External battery chargers Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle Onboard battery chargers Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 36 and 6 34 If wires are removed or replaced make sure wiring and wire harness are properly routed and secured Failure to properly route
190. not clean and tight excessive heat will be created and the charger may become damaged Page 4 16 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures DISCONNECTED SECONDARY COIL WIRE Figure 4 14 Diode Test Figure 4 15 Diode Test Probes Reversed Test Procedure 4B Both Diodes Failed See General Warning Section 1 Page 1 1 To check the diodes use Test Procedure 4A Single Diode Failure on page 4 16 If both diodes have failed closed both charger fuse links 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 breaker 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 Figure 4 2 Page 4 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 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 th
191. ns are tightened to 22 in Ib 2 5 N m 5 Ensure that the charger and vehicle are wired properly and all connections are clean and tight 2008 Export Battery Charger Maintenance and Service Manual Page 5 19 Is EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures TEST PROCEDURE 5 CHARGER DC CIRCUIT CONTINUITY TEST See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 1 2 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Using a continuity tester CCI P N 1011273 or multimeter CCI P N 1011480 set to 200 ohms connect the test probes to the pins marked and on the DC plug Figure 5 13 Page 5 20 Note the read ing Reversethe test probes and check the DC plug again Figure 5 14 Page 5 20 The circuit should show continuity in only one direction 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 5 22 Also check the diodes heatsink See Test Procedure 4 Diodes on page 5 18 If the circuit shows continuity in both directions a short circuit exists in the charger DC circuit usually caused by failed diodes See Test Procedure 4 Diodes on page 5 18 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 5 22 Remove the DC cord blu
192. oes not indicate continuity replace the AC circuit breaker 2008 Export Battery Charger Maintenance and Service Manual Page 6 23 6 EXPORT IQ PLUS CHARGER ONBOARD Charger Repairs CHARGER REPAIRS See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 6 4 Page 6 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 DC CORD DC Cord Removal 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 Remove the charger cover 9 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 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink Remove the wire tie that secures the DC cord wire to the secondary coil wire tan Remove the wire tie on the DC cord near the strain relief bushing Disconnect the DC cord blue wire from the control board Figure 6 17 Page 6 24 o NDARA Using pliers squeeze the strain relief bushing and remove the DC cord Figure 6 17 Page 6 24 DC CORD BLUE WIR
193. om charger mounting brack ets Figure 4 28 Page 4 35 Figure 4 28 Onboard Charger Mounting DS Villager 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 the positive post of battery no 1 See Section 1 General Warning 5 Disconnect the 10 gauge charger DC cord blue wire 17 from the 3 way wire adapter 18 at the sense lead fuse 20 Figure 4 29 Page 4 36 6 Cut any wire tie s that secures the DC cord to the vehicle 7 Lift charger and reel assembly from vehicle 2008 Export Battery Charger Maintenance and Service Manual Page 4 35 EXPORT POWERDRIVE CHARGER ONBOARD Onboard Charger Removal and Installation Figure 4 29 Charger DC Cord Black Wire and Blue Wire DS Villager 4 Onboard Charger Installation 1 Installation is reverse of removal 2 Tighten hardware securing the black DC cord wire to 23 in Ib 2 6 N m and the red DC cord wire to 144 in Ib 16 N m 3 Install four bolts 21 flat washers 22 lock washers 23 and nuts 24 securing charger to chassis and tighten to 108 in Ib 12 N m Figure 4 28 Page 4 35 4 Connect battery cables positive cable first and tighten to 144 in Ib 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
194. on the back of the charger is set for the appropriate incoming AC voltage Also ensure that the secondary coil wires are not touching one another With the relay bypassed insert the AC plug into an outlet If the AC line fuse blows or AC circuit breaker trips the trans former is shorted internally and must be replaced 7 Ifthe AC line fuse does not blow or the AC circuit breaker does not trip check the transformer secondary coil voltage 2008 Export Battery Charger Maintenance and Service Manual Page 4 19 EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures 8 Disconnect AC cord from the wall outlet 9 Using alligator clips and a multimeter set to 500 volts AC connect the multimeter probes to the second ary transformer coil tan wires Figure 4 18 Remove Secondary Coil Wires From Heatsink 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 Ifthe voltage reading is normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuity of the DC circuit See Test Procedure 5 Charger DC Circuit Continuity Test on page 4 18 12 When troubleshooting and repairs are complete remove jumper wire and properly connect relay wiring See following WARNING
195. onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge IQ Plus chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service disconnect the AC cord from the wall outlet wait 15 seconds and then plug the AC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before putting it into service 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 AC power to charger is interrupted 2 automatic charger shut off occurs after 16 hours of operation or 3 charger malfunctions the battery warning light will indicate as follows The battery warning light will not illuminate if the charge is 90 or more complete The onboard com puter will retain in memory the amount of charge needed to fully replenish the batteries and will com plete the charge during the next charge cycle Whe
196. onnect the AC and DC cords and remove the 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 Disconnect the black wire from relay terminal 6 4 3 Useajumper wire with alligator clips to connect the black wire from relay terminal 9 to the black wire from relay terminal 6 Figure 6 22 Page 6 33 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 the black wire from relay terminal 7 to the black wire from relay terminal 4 Figure 6 22 Page 6 33 See following DANGER 2008 Export Battery Charger Maintenance and Service Manual Page 6 31 ES EXPORT IQ PLUS CHARGER ONBOARD Charging a Battery Pack that has Low Voltage A 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 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 6 34 6 Plug the AC cord into an electrical outlet 7 The charger should activate and
197. pin connector 1 Figure 4 30 Page 4 37 3 Remove four bolts 2 flat washers 3 lock washers 4 and nuts 5 securing charger to chassis 4 Lift charger assembly from vehicle Page 4 36 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Onboard Charger Removal and Installation 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 Ib 12 N m 3 Connect battery cables positive cable first and tighten to 110 in Ib 12 4 N m Figure 4 30 Onboard Charger Mounting Precedent Vehicles 2008 Export Battery Charger Maintenance and Service Manual Page 4 37 SECTION 5 EXPORT IQ PLUS CHARGER EXTERNAL A DANGER See General Warning Section 1 Page 1 1 A WARNING See General Warning Section 1 Page 1 1 The battery charger DC plug must be pulled slowly from the receptacle Figure 5 4 Page 5 7 Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Figure 5 5 Page 5 7 GENERAL INFORMATION This section includes information pertaining to service of the Export IQ Plus battery charger model numbers 25880 11 and 25880 18 Depending on the geographic region the charger provided with your vehicle may be a different model Do not attempt to service a battery charger th
198. pted 3 automatic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light will not illuminate if the charge is 9096 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 DC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals during a charge cycle with the DC plug still connected if AC power to the charger is interrupted The light will go out when AC power is restored Page 5 2 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL The Charge Circuit EN THE CHARGE CIRCUIT The vehicle charge
199. r 3 Using two wrenches to prevent the posts from turning disconnect the DC cord black wire 5 and the buss bar 3 from the ammeter Figure 6 19 Page 6 27 4 Remove the two nuts 2 that secure the ammeter to the charger face 5 Remove the ammeter from the face of the charger Figure 6 19 Ammeter Ammeter Installation 1 Place the ammeter in position in the charger face Figure 6 19 Page 6 27 Install nuts 2 and tighten until ammeter is firmly secured Connect the DC cord black wire 5 to the left as viewed from inside the charger post of the ammeter moo omm 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 Thread nuts 4 onto both posts of ammeter until just past finger tight While holding the inside nut tighten the outside nut 4 1 4 turn See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 2008 Export Battery Charger Maintenance and Service Manual Page 6 27 6 EXPORT IQ PLUS CHARGER ONBOARD Charger Repairs 6 T Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 6 34 Check charger for proper operation FUSE LINK See General Warning Section 1 Page 1 1 Fuse Link Removal 1 Disconnect the DC cord the AC cord from the wall outlet and remo
200. r Disconnect all wires from the relay Figure 6 20 Page 6 29 Remove the two screws and nuts attaching relay to mounting bracket Remove the relay Charger Relay Installation Install in reverse order of removal Connect wires as shown Figure 6 20 Page 6 29 Tighten nuts securing relay to mounting bracket to 18 in Ib 2 0 N m Page 6 28 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Charger Repairs EN CONTROL BLUE WIRE TO BOARD CHARGER RELAY a eos Z FB d AC CIRCU BREAKERS AC CORD N BOTTOM VIEW OF RELAY STRAIN RELIEF BUSING BLACK WIRES TO BLACK OR PRIMARY COIL BROWN WIRE GREEN TOCONTROL OR BLACK WIRES BOARD GREEN TO VOLTAGE YELLOW INPUT SWITCH GROUND WIRE Figure 6 20 Charger Relay CHARGER AC CIRCUIT BREAKER See General Warning Section 1 Page 1 1 AC Circuit Breaker Removal 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 See WARNING on page 6 24 Remove the charger cover Disconnect the two black wires attached to top circuit breaker Figure 6 20 Page 6 29 Disconnect the two black wires attached to bottom circuit breaker Qr dm c qM 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 th
201. r Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Onboard Charger Operation 6 To check the charge circuit check the connections between the 18 gauge gray wire from the OBC DC cord red wire DC cord black wire and the wire connections between the batteries SOLID STATE ONBOARD SPEED CONTROLLER COMPUTER TUN Y No 4 BLACK No 10 RED Carryall 6 e POSITIVE Transporter 4 and 6 TERMINAL Villager 6 and 8 Connector SOLENOID No 10 RED Turf 2 and 252 Carryall 2 and 252 f Three Pin BLACK TO ONBOARD NEGATIVE BATTERIES CHARGER TERMINAL Figure 6 2 Charge Circuit ONBOARD CHARGER OPERATION See General Warning Section 1 Page 1 1 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A 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 phas
202. r and Continuity Check of AC Circuit on page 6 13 Onboard computer malfunction Test Procedure 2 Control Board on page 6 12 Charger failure See Testing Charger Operation on page 6 6 16 hour time out See Battery Warning Light on page 6 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Batteries are getting close to full discharge capacity Recharge batteries as soon as possible 2008 Export Battery Charger Maintenance and Service Manual Page 6 9 ES EXPORT IQ PLUS CHARGER ONBOARD Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 INDEX OF TEST PROCEDURES Battery Voltage Control Board AC Power and Continuity Check of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test oe 400 RoN G Continuity TEST PROCEDURE 1 BATTERY VOLTAGE See General Warning Section 1 Page 1 1 1 Check the wire connections between the vehicle and battery charger Figure 6 2 Page 6 3 1 1 Verify that the 10 gauge red wire from the battery charger is connected to the positive post of battery no 1 for Turf 2 252 Carryall 2 252 and XRT 900 vehicles or the large post of 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
203. r cover 4 Disconnect the green or green yellow wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 4 19 Page 4 22 o Disconnect the black or brown wire 1 of the short AC cord from the control board 6 Disconnect the AC cord white or blue wire 4 from the control board Figure 4 19 Page 4 22 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 4 19 Page 4 22 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 should indicate continuity on one flat blade only If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other 8 Place the red probe on the end of the green or green yellow wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug on the retractable cord reel Figure 4 19 Page 4 22 The tester should indicate continuity on only the round pin If any other read ing is obtained 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 o
204. r green yellow wire 2 from charger case and position it so it does not touch any Remove the charger cover metal part of the charger Figure 6 13 Page 6 19 Disconnect the black or brown wire 1 of the short AC cord 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 10 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 should indicate continuity on one flat blade only If any other reading is obtained the short AC cord and retractable cord reel must be tested independently of each other Place the red probe on the end of the green or green yellow wire 2 and with the black probe check for continuity on both flat blades and on the round pin of the AC plug on the retractable cord reel Figure 6 13 Page 6 19 The tester should indicate continuity on only the round pin If any other read ing is obtained the short AC cord and retractable cord reel must be tested independently of each other 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 bl
205. r overcharging Figure 3 1 PowerDrive Battery Charger Export 2008 Export Battery Charger Maintenance and Service Manual Page 3 1 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL General Information POWERDRIVE CHARGER FEATURES Charge Interlock PowerDrive battery charger DC plugs have three pins rather than two blades that most standard charger plugs have Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead that is the communication link between the charger and the onboard com puter When the charger plug is plugged into the vehicle receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge PowerDrive chargers are designed to be left connected with AC power to the charger during off sea son or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service disconnect the DC cord from the vehicle wait 15 seconds and plug the DC cord back in See following WARNING The charger will activate Allow the vehicle to complete one full charge cycle before putting it into service A WARNING The charger plug must be pulled slowly from the receptacle Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug
206. rd Charger Removal on page 4 35 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 continuity replace the AC circuit breaker CHARGER REPAIRS See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 4 5 Page 4 7 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 4 35 DC CORD DC Cord Removal 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 4 35 2 Remove the charger cover e SO Oe SB 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 Remove nut attaching the red wire 6 of the charger DC cord to the heatsink Remove the wire tie that secures the DC cord wire to the secondary coil wire tan Remove the wire tie on the DC cord near the strain relief bushing Disconnect the DC cord blue wire from the control board Figure 4 23
207. rd of the second charger connected to the AC outlet that it normally is connected to This will ensure that AC power is present Test Procedures 2 Check the AC circuit breakers on the front of the charger and reset if necessary 3 Insertthe DC cord from the second charger into the receptacle of the vehicle that is not charging properly 4 Ifthe second charger fails in the same manner as the first charger then the vehicle charging circuit is not functioning properly See Troubleshooting on page 3 14 5 Connect the first charger into another vehicle that is known to be functioning properly If the charger per forms as it should then the charger is 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 3 1 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle Check the AC circuit breakers on the front of the charger and reset if necessary 2 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 voltage for your area have building wiring checked by a licensed electrical contractor S
208. re Figure 4 10 Page 4 14 3 Multimeter should indicate full battery voltage approximately 47 50 volts If reading is incorrect replace control board 2008 Export Battery Charger Maintenance and Service Manual Page 4 13 EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures qm ccu BLUE WIRE RED WIRE DC TO RELAY d BLACK WIRE 200 DCV SETTING WHITE OR BLUE FROM RELAY WIRE FROM AC CORD Figure 4 10 DC Circuit Test Figure 4 11 AC Circuit Test AC Circuit Test 1 Disconnect AC cord from outlet DC cord red black and 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 4 12 Page 4 14 See fol lowing DANGER A 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 terminal with black wire from relay Connect red probe to 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 BLACK WIRE TO RELAY WIRE OF AC CORD a BLACK WIRE TO RELAY RED WIRE TO RELAY Ne D 4 Ya WHITE OR BLUE BLACK OR BROWN y BLUE WIRE TO RELAY WIRE OF AC CORD m S
209. re 5 21 Voltage Suppressor CHARGER RELAY See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 Charger Relay Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See WARNING on page 5 27 Remove the charger cover Disconnect all wires from the relay 00 Figure 5 7 Page 5 13 Boom 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 Ib 2 0 N m CHARGER AC CIRCUIT BREAKERS See General Warning Section 1 Page 1 1 See additional WARNING on page 5 1 AC Circuit Breaker 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 Page 5 32 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Charger Repairs E 3 Disconnect the two black wires attached to top circuit breaker Figure 5 6 Page 5 9 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 Circuit Breaker Inst
210. rent amps at 220 VAC 60 Hz 6 3 6 3 Max AC current amps at 240 VAC 50 Hz 5 9 5 9 Max AC current amps at 240 VAC 60 Hz 5 1 5 1 DC OUTPUT DC voltage VDC start of charge cycle 48 48 DC current amps start of charge cycle 17 17 DC voltage VDC end of charge cycle 60 60 DC current amps end of charge cycle 3 5 3 5 DIMENSIONS WEIGHT Case overall length 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 2008 Export Battery Charger Maintenance and Service Manual Page 2 1 CHARGER IDENTIFICATION AND SPECIFICATIONS Battery Charger Specifications EXPORT POWERDRIVE EXTERNAL CHARGER EL era SP ECIFICATIONS Battery Charger MODEL NUMBER 18780 11 18780 18 CCI P N 101831503 101831504 Case overall height 9 0 in 22 9 cm 9 0 in 22 9 cm AC cord length 72 in 182 9 cm 108 in 274 3 cm DC cord length 103 in 261 6 cm 144 in 365 8 cm Weight 35 Ib 15 9 kg 35 8 Ib 16 2 kg MOUNTING CONFIGURATION Mounting Set on shelf wall mount with keyhole or hang securely from ceiling EXPORT POWERDRIVE ONBOARD CHARGER SPECIFICATIONS Export PowerDrive Onboard Battery Charger Model number 17790 10 17790 11 17790 12 17790 40 CCI P N 101831601 1018
211. rge cccsssssssssesssessee 5 22 batteries 8 continuity battery condition after a charge cycle 5 8 AC circuit breaker internal 5 27 charging batteries that have low voltage 9 34 AC cord and plug sseese 5 22 state of charge test 5 22 ammieler ein secte ido 5 27 battery charger DC cord eec dtecdutue de ER NS ete 5 24 Operation einen ee Enc o prece eres 5 6 relays dine i edd uidi de cse 5 26 Tepas cerpin 5 27 transfOrtmier ien ea 5 25 HOSTING 3 2 ectetuer Sang tae 5 9 voltage suppressor cerren 5 26 2008 Export Battery Charger Maintenance and Service Manual Page i 1 INDEX transformer installation 5 ttn 5 29 removal 5m INIM 5 29 testirigas irse e E Rene 5 20 troubleshooting sees 5 10 voltage suppressor ssssesese 5 31 installation sisarien eais 5 32 removal sedie tiaia 5 31 testing ein tinet tet te E eoe teneis 5 26 IQ Plus charger onboard AC cord short Installations ocior Ae 6 30 REMOVAL sc 2 e ED RETE case Ei 6 29 ammeter installation 3 iere tr ERR Deed 6 27 removal x ncn Eee ua 6 27 i e 6 23 batteries battery condition after a charge cycle 6 7 charging batteries that have low voltage 6 31 state of charge test ccecce 6 18 battery charger installation site sche Reit oe teg 6 34 removal eec ederet ERR RRESES 6 34 repairs 5 pe
212. rger 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 All electric vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 1 Page 1 4 through Figure 1 10 Page 1 6 IQ System and IQ Plus vehicles Place Tow Run switch in the TOW position before disconnecting or connecti
213. rminal with black wire from relay Connect red probe to terminal from which the white or blue AC cord wire was disconnected Figure 6 7 Page 6 12 4 Connect AC cord to outlet Reading should be input voltage from outlet 5 If reading is incorrect replace control board Page 6 12 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Test Procedures 6 BLACK WIRE FROM RELAY BLACK OR BROWN WIRE x FROM AC CORD BLUE WIRE FROM RELAY LA BLACK WIRE FROM M RELAY WIRE FROM AC CORD RED WIRE FROM RELAY Inc ae eMe RED WIRE FROM HEATSINK BLUE WIRE FROM DC CORD Figure 6 8 Control Board TEST PROCEDURE 3 AC POWER AND CONTINUITY CHECK OF AC CIRCUIT See General Warning Section 1 Page 1 1 1 Disconnect the AC power supply cord from the wall outlet 2 Check the AC circuit breakers on the front of the charger and reset it 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 voltage for your area have building wiring checked by a licensed electrical contractor SETTING ON AC VOLTAGE MINIMUM AC VOLTAGE MAXIMUM AC VOLTAGE SELECTOR SWITCH PERMITTED PE
214. rom the wall outlet and the DC plug from the vehicle charger receptacle DC CORD See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 DC Cord Removal 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle See preceding WARNING 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 coil terminal Figure 3 27 Page 3 27 6 Remove wire ties securing the blue wire to the black transformer wire Note the location of the wire ties 7 Using pliers squeeze the strain relief bushing and remove the DC cord Figure 3 28 DC Cord Replacement DC Cord Installation 1 Insert the leads of the new DC cord through the hole in the charger base 2 Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18 in Ib 2 0 N m Figure 3 27 Page 3 27 Page 3 30 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Repairs 3 Attach the blue wire of the new DC cord to the blue wire of the voltage suppressor assembly connected
215. rotection may result in a fire See Battery Charger Specifications Section 2 Page 2 1 for maximum current draw Improper connection of the equipment grounding conductor can result in an electrical shock Do not use an adapter to plug charger into a two blade outlet or extension cord Extension cord or outlet must accept grounded three blade plug The use of an improper extension cord could result in fire or electric shock Chargers can ignite flammable materials and vapors Do not use near fuels grain dust solvents thinner or other flammables Keep charger dry Do not expose to rain Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other materials to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes 2008 Export Battery Charger Maintenance and Service Manual Page 3 9 EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Charger Installation and Operation Figure 3 8 Charger Receptacle Figure 3 9 Incorrect DC Plug Removal 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 suff
216. rs the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering column in the center dash panel will illu minate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart See Trouble shooting on page 5 10 If the specified test procedures identify no problems plug the DC cord into the vehi cle and let it charge until the charger shuts off automatically If a problem is found correct it and charge the vehicle Normal battery voltage near the end of a charge cycle should be approximately 59 to 63 volts DC 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 Page 5 8 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Checking Battery Condition with an External Charger EX 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 are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes TESTING CHARGER OPERATION 1 With the DC plug disconnected from the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the
217. rt Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL DC Cord 1 Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle 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 3 27 Page 3 27 4 Disconnect the red wire of the DC cord from the heatsink 5 Disconnect the blue wire from the red wire assembly that connects to the charger relay 6 Place the clip of the continuity tester on the red wire of the DC cord 7 Place the continuity test probe on the positive pin of the DC plug positive and negative pins are identified on the plug If tester does not indicate continuity the DC cord must be replaced 8 Place the continuity test probe on the negative pin of the DC plug The 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 of the DC plug The tester should indicate conti nuity If tester does not indicate continuity the DC cord must be replaced 12 Place the continuity test probe on the unmarked middle pin of th
218. rter 4 and 6 Tighten four bolts 7 and locknuts 8 to 65 in Ib 7 3 N m Carryall 2 252 Turf 2 252 XRT 900 Carryall 6 and Transporter 4 and 6 Tighten four screws 1 securing the cord reel housing 2 and its backing plate 3 to 16 in Ib 1 8 N m Place new heatshrink tubing over the short AC cord and connect the short AC cord to the retractable cord reel Slide the tubing over the connection and carefully apply heat to shrink it Page 6 30 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Charging a Battery Pack that has Low Voltage 6 TURF 2 AND 252 CARRYALL 2 AND 252 XRT 900 TRANSPORTER 4 VILLAGER 6 TRANSPORTER 6 VILLAGER 8 CARRYALL 6 Figure 6 21 Retractable Cord Reel Mounting Details CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See General Warning Section 1 Page 1 1 A WARNING Knowledge of battery charger wiring and component terminology is required before attempting any repair Figure 6 4 Page 6 6 Prior to servicing the charger disconnect the AC power supply cord from the wall outlet disconnect the DC cord from the vehicle and remove the battery charger from the vehicle See Onboard Charger Removal on page 6 34 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be bypassed to activate the charger 1 Turn key switch OFF and place the Forward Reverse switch in the NEUTRAL position 2 Disc
219. ructions in the language of the user should be printed on or permanently affixed to the top of the charger If these instructions are not found on the charger contact your Club Car representative 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 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 with your charger has the proper AC plug for your location If it does not contact your Club Car representative to obtain the proper cord or plug With charger DC cord disconnected connect the power supply cord to an AC supply within the acceptable voltage range See Section 2 Charger Identification and Specifications To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded
220. ry coil wire from the diode terminal Figure 3 21 Page 3 23 probe to the diode mounting plate and the black test probe to a diode terminal and note the reading Figure 3 21 Page 3 23 Reverse test probes and check each diode again and note the reading Figure 3 22 Page 3 23 A diode is designed to conduct current in one direction only If a diode conducts current shows continuity in both directions the entire heatsink with diodes must be replaced If a diode does not conduct current does not show continuity in either direction the entire heatsink must be replaced Page 3 22 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures DERI Disconnect secondary SX coil lead Figure 3 21 Diode Test Figure 3 22 Diode Test Probes Reversed 6 On rare occasions a single fuse link may blow due to excessive heat This can be caused by a loose internal fuse connection Check all three fuse connections inside the charger to be sure they are clean and tight The proper tightness for the fuse link connections is 22 in Ib 2 5 N m 7 Ensure the charger is wired properly and all connections are clean and tight See following CAUTION CAUTION f connections are not clean and tight excessive heat will be created and the charger may become damaged Test Procedure 4B Both Diodes Failed See General Warning Section 1 Page 1 1 See a
221. s an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals during a charge cycle with the DC plug still connected if AC power to the charger is interrupted The light will go out when AC power is restored Page 3 2 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL The Charge Circuit 3 THE CHARGE CIRCUIT DS DS VILLAGER 4 800 810 AND 850 The vehicle charge circuit consists of the following components charger receptacle receptacle fuse link sense lead fuse onboard computer batteries The negative terminal of the receptacle is connected to the onboard computer Figure 3 2 Page 3 3 The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the controller B terminal goes through the onboard computer and connects to the negative post of battery no 4 The positive terminal of the 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 circu
222. sformer secondary coil wires from the heatsink Figure 5 15 Page 5 21 Battery Pack that has Low Voltage on page 5 34 See following DANGER Page 5 20 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL Test Procedures EX A 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 5 Make sure that the voltage selector switch on the back of the charger is set for the appropriate incoming AC voltage Also ensure that the secondary coil wires are not touching one another With the relay bypassed insert the AC plug into an outlet If the AC line fuse blows or AC circuit breaker trips the trans former is shorted internally and must be replaced Figure 5 15 Remove Secondary Coil Wires From Heatsink 6 Ifthe AC line fuse does not blow or the AC circuit breaker does not trip check the transformer secondary coil voltage 7 Disconnect AC cord from the wall outlet 8 Using alligator clips and 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 Ifthe voltage
223. sult in charger malfunction property damage or severe personal injury 7 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 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 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 Place heatsink against charger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts that secure the heatsink to the case Tighten the bolts to 22 in Ib 2 5 N m 2 Connectthe red wire from the DC cord and the red wire from the control board to the center terminal post on the heatsink Figure 4 5 Page 4 7 Tighten nut to 18 in Ib 2 0 N m 2008 Export Battery Charger Maintenance and Service Manual Page 4 27 EXPORT POWERDRIVE CHARGER ONBOARD Charger Repairs 3 Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Figure 4 18 Page 4 20 Connect the other secondary coil transformer wire tan to the top terminal post of the heatsink Tig
224. t on page 3 2 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Battery warning light illuminates for ten seconds at four second intervals with DC charger cord disconnected 25 seconds at 10 second intervals for Precedent vehicles Batteries are getting close to full discharge capacity Recharge batteries Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 21 Battery or batteries need to be replaced See Batteries section in the appropriate maintenance and service manual Page 3 16 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Troubleshooting DIODE AND HEATSINK PRIMARY COIL SECONDARY COIL Figure 3 12 PowerDrive Battery Charger Export Exploded View 2008 Export Battery Charger Maintenance and Service Manual Page 3 17 ES EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures TEST PROCEDURES See General Warning Section 1 Page 1 1 See additional WARNING on page 3 1 INDEX OF TEST PROCEDURES Battery Voltage and DC Plug and Receptacle Onboard Computer AC Power and Continuity Test of AC Circuit Diodes Charger DC Circuit Continuity Test Transformer Battery State of Charge Test ON Oo O1 WD Continuity TEST PROCEDURE 1 BATTERY VOLTAGE
225. te eee e queat bae eode gts 6 24 testing ree eec te eed ees 6 6 battery condition after a charge cycle 6 7 battery warning light sseesseuusuesss 6 2 charge circuit onnios a ea 6 2 circuit breaker installati nir caita artara aiai 6 29 removal niii eiiie deau iei 6 29 testing zt ert tie Do RH RE 6 23 control board Iur 6 12 cord charger see AC cord or DC cord DC cord installation seeessessseseee 6 24 remoVal eie tete tet E 6 24 testing rnnt n 6 16 6 21 diodes charger see heatsink electrical system charge circuit nre tete 6 2 fuse link installation teet 6 28 temoVal Seti erm A See at aire 6 28 heatsink installatiOhi o otto tee eter oen 6 25 temoVal 31e eite mti re tet eatem 6 25 LOSE hs eee eme 6 14 relay installation seeeeesseseeeen 6 28 removal e RR I 6 28 COSTING es at RR REM ERES 6 23 retractable AC cord reel instalation aenea 6 30 FEMOVA aee eee erre ee vea pied 6 30 testingi iu io tote uit prae t e nns 6 20 test procedures 1 faulty receptacle connection 6 10 1 low battery voltage eeessses 6 10 2 control board esses 6 12 3 AC cord continuity check 6 13 3 AC DpOWer erect eene cs 6 13 4 dlodes 2 5 d neo idee 6 14 5 DC circuit continuity test
226. tel 5 22 abd E D MEE testing 3 9 weave rte seitens 5 20 5 24 B diodes charger see heatsink battery charger electrical system identification essere 2 6 charge circuit tee 5 3 specifications esses 2 1 fuse link INSTAL AON iui cerit eet hcic 5 31 C removal 2 ure de ona sg 5 31 CAUTION heatsink definitiontof sore eoo ts cree e e tete 1 1 installation esses 5 28 removal edere 5 28 D cupo 5 18 DANGER onboard computer definition of 2 2 ceceeccceccccccecccaceececeececeeeeceeeraneeneeess 1 1 testing 5 ee rie tricens 5 17 diodes charger relay see heatsink installation ne eee 5 32 reimoVal sis case sos a e aca regm teer reti nei Me 5 32 l TESTING cceann nnii oaeiai iia 5 26 identification of battery charger 2 6 suppressor voltage see voltage suppressor IQ Plus charger external testprocedures AC circuit breaker charger 1 faulty receptacle connection 5 14 pm ur 1 low battery voltage eese 5 14 see circuit breaker AC cord 2 onboard computer e E qiiis 5 17 TESTING niire ene e ieaie 5 22 AEA COTS COUI CSE dana a ei Peer 3 AC power sss 5 17 j 4 diodes ee 5 18 installation i a 5 30 5 DC circuit continuity test c 5 20 remoVal 555 E E 5 30 ERR 5 20 testing MH E eae te heen Ste REPERI 5 27 7 battery state of Cha
227. tery Pack that has Low Voltage on page 3 37 See following DANGER Page 3 24 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE BATTERY CHARGER EXTERNAL Test Procedures ERI A 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 5 Make sure that the voltage selector switch on the back of the charger is set for the appropriate incoming AC voltage Also ensure that the secondary coil wires are not touching one another With the relay bypassed insert the AC plug into an outlet ys PA Figure 3 25 Remove Secondary Coil Wires From Heatsink 6 Ifthe AC line fuse does not blow or the AC circuit breaker does not trip check the transformer secondary coil voltage 7 Disconnect AC cord from the wall outlet 8 Using alligator clips and a multimeter set to 500 volts AC connect the multimeter probes to the second ary transformer coil wires 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 Ifthe voltage reading is normal 86 volts AC or higher the transformer is operational Disconnect the AC plug from the wall receptacle and check the continuity of the DC circuit See
228. tery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures 3 Style C 6 x 8 Volt Precedent 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 6 Figure 4 9 Page 4 13 Figure 4 9 Battery Voltage Test Precedent Style C Battery Configuration Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 4 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 charger relay If battery pack voltage is too low to start charger temporarily bypass the charger relay See Charging a Battery Pack that has Low Voltage on page 4 33 TEST PROCEDURE 2 CONTROL BOARD See General Warning Section 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 A 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 probe of multimeter on terminal with blue DC cord wire and red probe to terminal with red relay wi
229. tette ee Paare ve ostro e due ugs 3 36 Charging a Battery Pack that has Low Voltage ssssseseene mene 3 37 SECTION 4 EXPORT POWERDRIVE CHARGER ONBOARD GeneralInformation 2 2 nin tete ctp RID A OO tati cpu ee ned 4 1 PowerDrive Onboard Charger Features sssssssessseseeeenee eene nnne 4 2 Battery Warming Light 2 123 eroe rcr ote no aUe Port MEI pert DAD R E etc e TA 4 2 The Charge Crett 22 de e en Ge Re Deko vena Re e tee OE E ee TE et un 4 2 Charger Operation oiii acabe unb cede tah adeeb teen hs tes teeta atas 4 4 AG Power Connections ces op repe d e ete Or ath aa tee status t nnde 4 4 Normal Charger Operation eese esee nnne nnne nnne nnne A E trennen 4 5 Testing Charger Operation seriei 2 pe rne od utet eee db t ee ete 4 6 Checking Battery Condition cecinere tenete E nene d nnne TE 4 8 Troubleshooting 2 2 cte de cen a pico v du duce ll e da edu dv dede de deu adea 4 8 liest PrOCedures dos atero reme Re 4 11 Indexcot Test PrOCedUres ou e De eR DR dre E Dru Dr ded ges 4 11 Charger Bepalls n te ente ie e ite Pee e oe rte de diee ASS 4 26 DIERE e i EE 4 26 Heatsink uv agde inn ea M E E PEDE 4 27 Transformer 5 s ico UE qood S EE cede itn ek eth EDU E 4 28 Ammeter i cols teci ee ce See a Ar se EPI UM E 4 29 Euse bink zc a e as A A A E et an Ru 4 30 Charger Relay 5er tur RR C Pei E RR ERE 4 30 Charger AG Circuit Breaker act t
230. the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 6 Connectthe black primary coil transformer wire marked 1 to the top terminal of the top AC circuit breaker 7 Connect the black primary coil transformer wire marked 6 to the top terminal of the bottom AC circuit 10 breaker Connect each of the remaining black primary coil transformer wires marked 2 3 4 and 5 to the corre sponding terminals marked on the voltage selector switch Set the voltage selector switch to the appropriate voltage matching the incoming AC electrical service that will be used to power the charger Tie the wires together as they were before the wire tie was removed See following WARNING A WARNING 11 12 Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 6 34 Check charger for proper operation Page 6 26 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER ONBOARD Charger Repairs EN AMMETER See General Warning Section 1 Page 1 1 Ammeter Removal 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 See WARNING on page 6 24 2 Remove the charger cove
231. the initial charge rate may also result from AC line input voltages that are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 4 Monitor the ammeter Under normal operating conditions when the charger is on and the batteries are discharged the charger will shut off in order to run a self diagnostic program ammeter will drop to zero one hour and two hours into the charge cycle See following CAUTION and NOTE CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage NOTE If the batteries are in a fully charged state and the vehicle has not been driven the onboard com puter will not perform the self diagnostic test after the charge cycle starts 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 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
232. to the relay coil terminal 4 Attach the black wire 4 of the new DC cord to ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the inside nut 2 tighten the outside nut 1 1 4 turn Figure 3 28 Page 3 30 See following CAUTION CAUTION Do not allow ammeter post to rotate as the nut is tightened Rotation of the post could result in a damaged ammeter 5 Using pliers put the strain relief bushing 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 A WARNING Make sure wiring is properly routed and secured Failure to properly route and secure wiring could result in charger malfunction property damage or severe personal injury 8 Position the charger cover on the base Install the mounting screws starting with the bottom holes Tighten the screws to 11 in Ib 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 11 Page 3 13 and Figure 3 12 Page 3 17 4 Remove the two red wires from the heatsink 5 R
233. ug or the vehicle receptacle is broken damaged or does not make a good electrical connection Fire or personal injury can result Have a qualified technician replace the parts 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 WARNING CONTINUED ON NEXT PAGE Page 5 4 2008 Export Battery Charger Maintenance and Service Manual EXPORT IQ PLUS CHARGER EXTERNAL External Charger Installation and Operation Fa A WARNING Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes A 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 NOTE Charger operation inst
234. upply was shut off Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 21 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 21 Batteries may be fully charged Test Procedure 7 Battery State of Charge Test on page 3 25 Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 21 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 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 intervals with DC charger cord plugged in 25 seconds at 10 second intervals for Precedent vehicles AC power interrupted Test Procedure 3 AC Power and Continuity Test of AC Circuit on page 3 21 Onboard computer malfunction Test Procedure 2 Onboard Computer on page 3 21 Charger failure See Testing Charger Operation on page 3 12 16 hour time out See Battery Warning Ligh
235. ure 4 17 DC Cord Test Probes Reversed DS Villager 4 Page 4 18 2008 Export Battery Charger Maintenance and Service Manual EXPORT POWERDRIVE CHARGER ONBOARD Test Procedures Test Procedure 5B Precedent Vehicles See General Warning Section 1 Page 1 1 1 Disconnect the AC cord from the wall outlet 2 Disconnect the batteries as instructed See General Warning Section 1 Page 1 1 3 Disconnect the charger DC cord at the three pin connector Figure 4 3 Page 4 3 4 Using a continuity tester CCI P N 1011273 or multimeter set to 200 ohms connect the test probes to the charger DC cord black wire and red wire terminals in the three pin connector Note the reading 5 Reverse the test probes and check the DC cord again The circuit should show continuity in only one direction 6 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 4 Diodes on page 4 16 7 If the circuit shows continuity in both directions a short circuit exists in the charger DC circuit usually caused by failed diodes See Test Procedure 4 Diodes on page 4 16 If diodes have not failed check the DC cord for a short circuit See Test Procedure 8 Continuity on page 4 21 8 Check continuity between the DC cord red black
236. ve the battery charger from the vehi cle See Onboard Charger Removal on page 6 34 See WARNING on page 6 24 2 Remove the charger cover 3 Remove both black secondary coil transformer wires and the buss bar 3 from the back of the fuse link 4 assembly Figure 6 19 Page 6 27 Remove screws from the front of the charger and remove the fuse 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 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 Ib 2 5 N m 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 Ib 2 5 N m Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 6 34 Check charger for proper operation CHARGER RELAY See General Warning Section 1 Page 1 1 Charger Relay Removal 1 BooN 5 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 See WARNING on page 6 24 Remove the charger cove
237. witch 9 and jumper wires Figure 5 7 Page 5 13 If the charger is wired correctly check the continuity of the AC cord transformer primary coil internal AC circuit breakers and the jumper wires individually See Test Procedure 8 Continuity on page 5 22 When troubleshooting and repairs are complete remove the jumper wire and properly connect the relay wiring See following WARNING A 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 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 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 from the wall outlet and DC plug from the vehicle receptacle 2 Remove the charger cover 3 4 Using a low voltage continuity tester or multimeter set to the diode test function connect the red
238. ws starting with the bottom holes Tighten the screws to 11 in Ib 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 Remove the charger cover Remove both secondary coil transformer wires tan from the heatsink Figure 6 12 Page 6 17 me Qd Remove the two red wires from the heatsink e Remove the nuts and bolts that secure the heatsink to the case Heatsink Installation 1 Place heatsink against charger base Make sure clear plastic insulator sheet is between the heatsink and the charger base Install the nuts and bolts that secure the heatsink to the case Tighten the bolts to 22 in Ib 2 5 N m 2 Connectthe red wire from the DC cord and the red wire from the control board to the center terminal post on the heatsink Tighten nut to 18 in Ib 2 0 N m Figure 6 4 Page 6 6 3 Connect one of the secondary coil transformer wires tan to the bottom terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m Figure 6 12 Page 6 17 4 Connect the other secondary coil transformer wire tan to the top terminal post of the heatsink Tighten nut to 18 in Ib 2 0 N m 5 Install the charger cover and install the charger in the vehicle See Onboard Charger Installation on page 6 34 6 Check charger for proper operation 2008 Export Battery Charger Maintenance and Service Manual Page 6 25

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