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Club Car PowerDrive User Manual

Club Car PowerDrive
24 pages
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POWERDRIVE
BATTERY CHARGER
OWNERS MANUAL
Manual Number 101993811
Edition Code 0898U0313T
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Club Car PowerDrive Specifications

General IconGeneral
Voltage48V
Input Voltage120V AC
Output Voltage48V DC
Cooling MethodFan cooled
Charger TypeAutomatic
CompatibilityClub Car golf carts with PowerDrive or PowerDrive Plus electrical systems

Summary

Important Notices

Liability and Copyright

Disclaims liability for errors and reserves copyright for manual content.

Subject to Change

Information is subject to change without notice; rights reserved.

Safety Details

Danger Hazard Definition

Indicates an immediate hazard that will result in severe personal injury or death.

Warning Hazard Definition

Indicates an immediate hazard that could result in severe personal injury or death.

Caution Hazard Definition

Indicates a hazard or unsafe practice that could result in minor injury or damage.

Caution (No Symbol) Definition

Indicates a situation that potentially could result in property damage.

General Information

Charger Configurations

Describes various PowerDrive charger configurations for domestic and international use.

Automatic Operation

Charger is automatic with a 2-15 second delay before charging begins.

IQ System Self-Diagnosis

Charger shuts off hourly for self-diagnosis and then resumes charging.

Onboard Computer Control

Computer directs charger to replenish exact energy needed, preventing under/overcharging.

External Charger Features

Charge Interlock System

Prevents vehicle drive system operation when charger is plugged in.

Long-Term Storage Mode

Charger automatically activates every 15 days for storage.

Warning: DC Cord Handling

Pull DC cord slowly to avoid arcing, burning, or battery explosion.

Caution: Monthly Checks

Check battery water level and charger operation monthly during storage.

Onboard Charger Features

Onboard Charge Interlock

Locks out vehicle drive system when AC power cord is inserted.

Battery Warning Light

Warning Light Indicators

Describes various illuminated states of the battery warning light.

Compliance Listings

UL and CSA Listing

Chargers listed by Underwriters Laboratories and Canadian Underwriters.

EU Compliance

Confirms compliance with the EU Low-Voltage Directive.

External Charger Installation and Operation

Danger: Ventilation and Enclosures

Ensure ventilation and remove enclosures during charging to prevent explosion.

Warning: Servicing and Electrical Safety

Only trained technicians should service; use dedicated circuits and proper connections.

Warning: Extension Cord Usage

Use proper gauge, short extension cords to prevent fire or shock.

Warning: Flammables and Liquids

Do not use near flammables or expose to rain; keep charger dry.

Warning: Cord and Slot Safety

Handle cords carefully; never insert objects into slots.

Warning: Compatibility and Damage

Connect compatible packs; do not use damaged plugs or cords.

External Charger AC Power Connection

AC Power Connection Guidelines

Connect to proper voltage/current outlet; set voltage switch before connecting.

Caution: Voltage Selector Switch

Failure to set voltage selector correctly can damage charger or batteries.

Grounding and Extension Cords

Charger must be grounded; avoid extension cords or use properly rated ones.

Charging Batteries - Safety

Do not bypass sense lead fuse (model dependent).

External Charger Plug and Receptacle

Plug Insertion and Removal

Align guide and push plug straight in; grasp plug to remove, do not pull cord.

Warning: Plug Handling Safety

Handle plug carefully to avoid arcing, burning, or battery explosion.

Warning: Damaged Components

Do not use if cord, plug, or receptacle is damaged; risk of fire/injury.

Checking Battery Condition (External)

Onboard Computer Monitoring

Onboard computer monitors charge cycle; warning light indicates problems.

Troubleshooting and Charging

Refer to manual for troubleshooting; charge until shut-off; check voltage.

Start Charge Cycle (External)

DC Cord Disconnection and Reconnection

Disconnect DC plug, wait 20s, then reconnect to vehicle receptacle.

Charge Cycle Behavior Notes

Monitor ammeter; self-diagnosis (zero drop) occurs if vehicle not driven or partially charged.

Onboard Charger Operation

Danger: Ventilation and Enclosures

Ensure ventilation and remove enclosures during charging to prevent explosion.

Warning: Servicing and Electrical Safety

Only trained technicians should service; use dedicated circuits and proper connections.

Warning: General Safety Precautions

Avoid flammables, liquids, covering charger, slot insertion, and damage.

Warning: Operational Limits

Do not operate if damaged, worn, or exceeding 30 min at 19+ amps.

Surge Protection

Install surge arrestors to protect components from lightning strikes.

Onboard Charger AC Power Connection

AC Power Requirements

Connect to proper voltage/current outlet; set voltage switch before connecting.

Caution: Voltage Selector Switch

Failure to set voltage selector correctly can damage charger or batteries.

Grounding and Extension Cords

Charger must be grounded; avoid extension cords.

Item Placement and Ventilation

Do not place items in compartment; ensure ventilation slots are unobstructed.

Charging Batteries (Onboard)

AC Connection and Activation

Connect AC cord; charger activates within 2-15 seconds.

Charge Rate and Self-Diagnosis

Monitor ammeter; self-diagnosis (zero drop) occurs at intervals during charging.

Caution: External Charger Conflict

Do not connect external charger when onboard charger is active; risk of overload.

Checking Battery Condition (Onboard)

Onboard Computer Monitoring

Onboard computer monitors charge cycle; warning light indicates problems.

Troubleshooting and Charging

Refer to manual for troubleshooting; charge until shut-off; check voltage.

Start Charge Cycle (Onboard)

AC Plug Disconnection and Reconnection

Disconnect AC plug, wait 20s, then reconnect to wall outlet.

Charge Cycle Behavior Notes

Monitor ammeter; self-diagnosis (zero drop) occurs if vehicle not driven or partially charged.

IQ System Self-Diagnosis Timing

IQ System chargers shut off hourly for self-diagnosis and then resume charging.

Domestic Charger Specifications

External Charger Models

Specifications for domestic PowerDrive external battery chargers.

Onboard Charger Models

Specifications for domestic PowerDrive onboard battery chargers.

Export External Charger Specifications

European Models

Specifications for European PowerDrive external battery chargers.

Export Models

Specifications for export PowerDrive external battery chargers.

Australian Models

Specifications for Australian PowerDrive external battery chargers.

Export Onboard Charger Specifications

Export Models

Specifications for export PowerDrive onboard battery chargers.

Club Car Limited Warranty

Warranty Coverage

Four-year warranty on PowerDrive chargers against defects in material and workmanship.

Warranty Exclusions

Excludes failures due to lack of maintenance, abuse, or improper use.

Warranty Limitations

Liability limited to repair/replacement; no implied warranties beyond stated terms.

Liability for Damages

Excludes incidental or consequential damages, loss of use, or economic loss.