Voltage Suppressor; Charger Relay; Charger Ac Circuit Breaker - Club Car 2008-2011 Maintenance And Service Manual

5
POWERDRIVE 2 CHARGER (EXTERNAL)

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 5-20.
Voltage Suppressor Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Disconnect the white wires (3 and 4) from the ammeter (Figure 5-20, Page 5-27).
4. Disconnect the white wire from the positive (+) terminal of the rectifier.
5. Disconnect the blue, red, and white wires from the relay.
6. Disconnect the DC cord blue wire at the quick disconnect terminal.
7. Remove the voltage suppressor and wire assembly from the charger.
Voltage Suppressor Installation
1. Install in reverse order of removal. See following NOTE.
NOTE: The charger relay blade connector is located off-center within the relay housing. When connecting
voltage suppressor slip-on connector to relay blade connector, make sure slip-on connector is
positioned so that flat side of connector is closest to relay housing.

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.
2. Remove the charger cover.
3. Disconnect all wires from the relay (Figure 5-6, Page 5-8).
4. Remove two screws, nuts, and lock washers attaching relay to the charger case.
5. Remove the relay.
Charger Relay Installation
1. Install in reverse order of removal. Connect wires as shown (Figure 5-6, Page 5-8). Tighten nut securing
relay to charger base to 18 in-lb (2.0 N·m).

CHARGER AC CIRCUIT BREAKER

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.
2. Remove the charger cover.
3. Disconnect the two black wires attached to the AC circuit breaker (Figure 5-6, Page 5-8).
Page 5-28 2008-2011 Domestic Battery Charger Maintenance and Service Manual
Charger Repairs