2008-2011 Club Car Domestic Battery Charger Service & Repair Manual
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Manual Number 103373121
Edition Code 0408D1010C
Domestic PowerDrive, IQ Plus and
High Frequency Battery Chargers
2008-2011 Domestic
Battery Charger
Maintenance and Service
Manual
4.
3.
1.
2.
MADE IN USA MADE IN USA
Club Car
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2008-2011 Domestic Battery Charger Maintenance and Service Manual Page i
FOREWORD
Club Car battery chargers are designed and built to provide unsurpassed performance efficiency among
chargers in their class; however, proper maintenance and repair are essential for achieving maximum service
life and continued safe and reliable operation.
This manual provides detailed information for the maintenance and repair of domestic Club Car battery charg-
ers, and should be thoroughly reviewed prior to servicing the charger. The procedures provided herein must
be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
This manual was written for the trained technician who already has knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to
the vehicle or charger may render the vehicle or charger unsafe. For this reason, Club Car advises that all
repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club
Car factory-trained technician.
It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
Club Car offers a full line of training and continuing education classes for technicians who want to learn more
about our products. For more information, contact your local dealer or Club Car’s Technical Services depart-
ment for a list of upcoming classes.
This manual covers all aspects of typical battery charger service; unique situations, however, do sometimes
occur when servicing a charger. If it appears that a service question is not answered in this manual, you may
write to us at: Club Car, LLC; P.O. Box 204658; Augusta, Georgia 30917; Attention: Technical Services.
Copyright © 2007, 2009, 2010 Club Car, LLC
Club Car and PowerDrive are registered
trademarks of Club Car, LLC.
This manual effective August 6, 2007.
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Page ii 2008-2011 Domestic Battery Charger Maintenance and Service Manual
ý WARNING
• Read Section 1 – Safety before attempting any service on a Club Car vehicle or charger.
• Before servicing a Club Car vehicle or charger, read complete section(s) and any referenced
information that may be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, LLC is
continually working to further improve our vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions
of this manual.
Club Car, LLC reserves the right to change specifications and designs at any time without notice
and without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to: Club Car, LLC, P.O. Box 204658, Augusta, GA 30917-4658,
USA, Attention: Warranty Administration.
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2008-2011 Domestic Battery Charger Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
Disabling The Vehicle ................................................................................................................... 1-3
Disconnecting The Batteries ......................................................................................................... 1-3
Connecting The Batteries ............................................................................................................. 1-4
SECTION 2 – CHARGER IDENTIFICATION AND SPECIFICATIONS
Battery Charger Identification ........................................................................................................... 2-1
Specifications .................................................................................................................................... 2-2
SECTION 3 – POWERDRIVE CHARGER (EXTERNAL)
General Information .......................................................................................................................... 3-1
PowerDrive External Charger Features ........................................................................................ 3-2
Battery Warning Light ................................................................................................................... 3-2
The Charge Circuit ............................................................................................................................ 3-3
DS, DS Villager 4, 800, 810 and 850 ............................................................................................ 3-3
Turf 1 and Carryall 1 ..................................................................................................................... 3-4
Precedent – 4 x 12-Volt ................................................................................................................ 3-5
Precedent – 6 x 8-Volt .................................................................................................................. 3-6
Charger Installation and Operation ................................................................................................... 3-8
AC Power Connection .................................................................................................................. 3-9
Charging Batteries ........................................................................................................................ 3-9
Testing Charger Operation ........................................................................................................... 3-11
DC Cord and Plug Inspection ....................................................................................................... 3-11
Checking Battery Condition After a Charge Cycle ............................................................................ 3-12
Start Charge Cycle ....................................................................................................................... 3-12
Troubleshooting ................................................................................................................................ 3-12
Test Procedures ............................................................................................................................... 3-16
Index of Test Procedures .............................................................................................................. 3-16
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Page iv 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charger Repairs ............................................................................................................................... 3-27
DC Cord ....................................................................................................................................... 3-27
Heatsink ....................................................................................................................................... 3-28
Transformer .................................................................................................................................. 3-29
Ammeter ....................................................................................................................................... 3-30
Fuse Link ...................................................................................................................................... 3-31
Voltage Suppressor ...................................................................................................................... 3-31
Charger Relay .............................................................................................................................. 3-32
Charger AC Circuit Breaker .......................................................................................................... 3-32
Charger AC Cord .......................................................................................................................... 3-32
Charging a Battery Pack that has Low Voltage ................................................................................ 3-34
SECTION 4 – POWERDRIVE CHARGER (ONBOARD)
General Information ......................................................................................................................... 4-1
PowerDrive Onboard Charger Features ....................................................................................... 4-2
Battery Warning Light ................................................................................................................... 4-2
The Charge Circuit ........................................................................................................................... 4-2
Charger Operation ........................................................................................................................... 4-4
Checking Battery Condition .............................................................................................................. 4-6
Troubleshooting ............................................................................................................................... 4-7
Test Procedures ............................................................................................................................... 4-9
Index of Test Procedures ............................................................................................................. 4-9
Charger Repairs ............................................................................................................................... 4-24
DC Cord ....................................................................................................................................... 4-24
Heatsink ....................................................................................................................................... 4-25
Transformer .................................................................................................................................. 4-26
Ammeter ....................................................................................................................................... 4-27
Fuse Link ...................................................................................................................................... 4-28
Charger Relay .............................................................................................................................. 4-28
Charger AC Circuit Breaker .......................................................................................................... 4-29
Charger AC Cord and Retractable Cord Reel .............................................................................. 4-29
Retractable AC Cord Reel ............................................................................................................ 4-30
Charging a Battery Pack that has Low Voltage ................................................................................ 4-31
Onboard Charger Removal and Installation ..................................................................................... 4-33
DS Villager 4 ................................................................................................................................ 4-33
Precedent Vehicles ...................................................................................................................... 4-34
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2008-2011 Domestic Battery Charger Maintenance and Service Manual Page v
SECTION 5 – POWERDRIVE 2 CHARGER (EXTERNAL)
General Information .......................................................................................................................... 5-1
PowerDrive 2 Battery Charger Features ....................................................................................... 5-2
Battery Warning Light ................................................................................................................... 5-2
The Charge Circuit ............................................................................................................................ 5-3
Charger Installation and Operation ................................................................................................... 5-4
AC Power Connection .................................................................................................................. 5-6
Charging Batteries ........................................................................................................................ 5-6
Testing Charger Operation ........................................................................................................... 5-7
DC Cord and Plug Inspection ....................................................................................................... 5-8
Checking Battery Condition After a charge Cycle ............................................................................. 5-9
Start Charge Cycle ....................................................................................................................... 5-9
Troubleshooting ................................................................................................................................ 5-9
Test Procedures ............................................................................................................................... 5-12
Index of Test Procedures .............................................................................................................. 5-12
Charger Repairs ............................................................................................................................... 5-23
DC Cord ........................................................................................................................................ 5-23
Rectifier ......................................................................................................................................... 5-24
Transformer .................................................................................................................................. 5-25
Ammeter ....................................................................................................................................... 5-26
Fuse Link ...................................................................................................................................... 5-27
Voltage Suppressor ...................................................................................................................... 5-28
Charger Relay ............................................................................................................................... 5-28
Charger AC Circuit Breaker .......................................................................................................... 5-28
Charger AC Cord .......................................................................................................................... 5-29
Charging a Battery Pack that has Low Voltage ................................................................................ 5-29
SECTION 6 – POWERDRIVE 3 – MODEL 26560
General Information .......................................................................................................................... 6-1
PowerDrive 3 Battery Charger Features ....................................................................................... 6-2
Battery Warning Light ................................................................................................................... 6-2
The Charge Circuit ............................................................................................................................ 6-3
DS, 800, 810 and 850 Vehicles – 4 x 12-Volt ............................................................................... 6-3
Turf 1 and Carryall 1 Vehicles – 6 x 8-Volt ................................................................................... 6-4
Precedent Vehicles – 4 x 12-Volt .................................................................................................. 6-5
Precedent Vehicles – 6 x 8-Volt .................................................................................................... 6-6
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Charger Installation and Operation .................................................................................................. 6-8
AC Power Connection .................................................................................................................. 6-9
Charging Batteries ........................................................................................................................ 6-9
Testing Charger Operation ........................................................................................................... 6-11
DC Cord and Plug Inspection ....................................................................................................... 6-11
Checking Battery Condition After a charge Cycle ............................................................................ 6-12
Start Charge Cycle ....................................................................................................................... 6-12
Troubleshooting ............................................................................................................................... 6-12
Test Procedures ............................................................................................................................... 6-16
Index of Test Procedures ............................................................................................................. 6-16
Charger Repairs ............................................................................................................................... 6-27
DC Cord ....................................................................................................................................... 6-27
Rectifier ........................................................................................................................................ 6-28
Transformer .................................................................................................................................. 6-29
Ammeter ....................................................................................................................................... 6-30
Fuse Link ...................................................................................................................................... 6-31
Relay Board Assembly ................................................................................................................. 6-32
Charger AC Circuit Breaker .......................................................................................................... 6-32
Charger AC Cord .......................................................................................................................... 6-32
Charging a Battery Pack that has Low Voltage ................................................................................ 6-34
SECTION 7 – POWERDRIVE 3 – MODEL 26580
General Information ......................................................................................................................... 7-1
PowerDrive 3 Battery Charger Features ...................................................................................... 7-2
Battery Warning Light ................................................................................................................... 7-2
The Charge Circuit ........................................................................................................................... 7-3
DS, 800, 810 and 850 Vehicles – 4 x 12-Volt ............................................................................... 7-3
Turf 1 and Carryall 1 Vehicles – 6 x 8-Volt ................................................................................... 7-4
Precedent Vehicles – 4 x 12-Volt ................................................................................................. 7-5
Precedent Vehicles – 6 x 8-Volt ................................................................................................... 7-6
Charger Installation and Operation .................................................................................................. 7-8
AC Power Connection .................................................................................................................. 7-9
Charging Batteries ........................................................................................................................ 7-9
Testing Charger Operation ........................................................................................................... 7-11
DC Cord and Plug Inspection ....................................................................................................... 7-11
Checking Battery Condition After a charge Cycle ............................................................................ 7-12
Start Charge Cycle ....................................................................................................................... 7-12
Troubleshooting ............................................................................................................................... 7-12
Test Procedures ............................................................................................................................... 7-16
Index of Test Procedures ............................................................................................................. 7-16
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2008-2011 Domestic Battery Charger Maintenance and Service Manual Page vii
Charger Repairs ............................................................................................................................... 7-28
DC Cord ........................................................................................................................................ 7-28
Diode/Heatsink ............................................................................................................................. 7-29
Transformer .................................................................................................................................. 7-30
Ammeter ....................................................................................................................................... 7-31
Fuse Link ...................................................................................................................................... 7-32
Relay Board Assembly ................................................................................................................. 7-32
Charger AC Circuit Breaker .......................................................................................................... 7-32
Charger AC Cord .......................................................................................................................... 7-33
Charging a Battery Pack that has Low Voltage ................................................................................ 7-34
SECTION 8 – IQ PLUS CHARGER (EXTERNAL)
General Information .......................................................................................................................... 8-1
IQ Plus External Charger Features ............................................................................................... 8-2
Battery Warning Light ................................................................................................................... 8-2
UL and CSA Listing ...................................................................................................................... 8-2
The Charge Circuit ............................................................................................................................ 8-3
External Charger Installation and Operation ..................................................................................... 8-4
External Charger AC Power Connection ...................................................................................... 8-5
Charging Batteries ........................................................................................................................ 8-5
External Charger Plug and Receptacle ........................................................................................ 8-7
Checking Battery Condition with an External Charger ...................................................................... 8-8
Start Charge Cycle ....................................................................................................................... 8-8
Testing Charger Operation ........................................................................................................... 8-8
Troubleshooting ................................................................................................................................ 8-9
Test Procedures ............................................................................................................................... 8-12
Index of Test Procedures .............................................................................................................. 8-12
Charger Repairs ............................................................................................................................... 8-23
DC Cord ........................................................................................................................................ 8-23
Heatsink ........................................................................................................................................ 8-24
Transformer .................................................................................................................................. 8-25
Ammeter ....................................................................................................................................... 8-26
Fuse Link ...................................................................................................................................... 8-27
Voltage Suppressor ...................................................................................................................... 8-27
Charger Relay ............................................................................................................................... 8-28
Charger AC Circuit Breaker .......................................................................................................... 8-28
Charger AC Cord .......................................................................................................................... 8-28
Charging a Battery Pack that has Low Voltage ................................................................................ 8-29
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Page viii 2008-2011 Domestic Battery Charger Maintenance and Service Manual
SECTION 9 – IQ PLUS CHARGER (ONBOARD)
General Information ......................................................................................................................... 9-1
IQ Plus Onboard Charger Features ............................................................................................. 9-2
Battery Warning Light ................................................................................................................... 9-2
UL and CSA Listing ...................................................................................................................... 9-2
The Charge Circuit ........................................................................................................................... 9-2
Onboard Charger Operation ............................................................................................................ 9-3
Onboard Charger AC Power Connection ..................................................................................... 9-4
Charging Batteries ........................................................................................................................ 9-4
Checking Battery Condition with an Onboard Charger .................................................................... 9-5
Start Charge Cycle ....................................................................................................................... 9-5
Testing Charger Operation ........................................................................................................... 9-6
Troubleshooting ............................................................................................................................... 9-6
Test Procedures ............................................................................................................................... 9-9
Index of Test Procedures ............................................................................................................. 9-9
Charger Repairs ............................................................................................................................... 9-22
DC Cord ....................................................................................................................................... 9-22
Heatsink ....................................................................................................................................... 9-23
Transformer .................................................................................................................................. 9-24
Ammeter ....................................................................................................................................... 9-24
Fuse Link ...................................................................................................................................... 9-26
Charger Relay .............................................................................................................................. 9-26
Charger AC Circuit Breaker .......................................................................................................... 9-27
Charger AC Cord and Retractable Cord Reel .............................................................................. 9-27
Retractable AC Cord Reel ............................................................................................................ 9-28
Charging a Battery Pack that has Low Voltage ................................................................................ 9-29
Onboard Charger Removal and Installation ..................................................................................... 9-31
SECTION 10 – HIGH FREQUENCY CHARGER (ONBOARD)
General Information ......................................................................................................................... 10-1
Features ....................................................................................................................................... 10-2
UL and CSA Listing ...................................................................................................................... 10-2
CE Compliance ............................................................................................................................ 10-2
IP (Ingress Protection) Rating ...................................................................................................... 10-2
How To Identify Charge Algorithm Number .................................................................................. 10-3
The Charge Circuit ........................................................................................................................... 10-4
Onboard Charger Operation ............................................................................................................ 10-4
Charger Displays .......................................................................................................................... 10-6
AC Power Connection .................................................................................................................. 10-7
Charging Batteries ........................................................................................................................ 10-7
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Print one or all pages of your manual
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The Club Car Domestic Battery Charger Service Manual 2008-2011 provides essential technical information for maintaining and repairing Domestic PowerDrive, IQ Plus, and High Frequency Battery Chargers. These manuals are valuable resources for both professional mechanics and DIY enthusiasts, offering detailed insights into the operation and servicing of these essential components.
