Fuse Link; Voltage Suppressor - Club Car 2008-2011 Maintenance And Service Manual

POWERDRIVE CHARGER (EXTERNAL)

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.
2. Remove the charger cover.
3. Remove both black secondary coil transformer wires and the buss bar from the back of the fuse link
assembly (Figure 3-26, Page 3-30).
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 3-26,
Page 3-30). Tighten to 22 in-lb (2.5 N·m).
3. Install a secondary coil transformer wire (black) onto one of the two remaining terminals on the back of
the fuse assembly. Install the remaining secondary coil transformer wire (black) onto the remaining ter-
minal. Tighten to 22 in-lb (2.5 N·m).
4. Install the charger cover.

VOLTAGE SUPPRESSOR

See General Warning, Section 1, Page 1-1. See additional WARNING on page 3-1.
The voltage suppressor, which is incorporated into a wire assembly in 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 3-24.
Voltage Suppressor Removal
1. Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle.
2. Remove the charger cover.
3. Remove nut attaching voltage suppressor (18-gauge red wire) to heatsink (Figure 3-27, Page 3-33).
4. Disconnect the blue and red wires from the relay.
5. Disconnect the DC cord blue wire at the quick disconnect terminal.
6. Remove the voltage suppressor and wire assembly from the charger.
Voltage Suppressor Installation
1. Install in reverse order of removal. Tighten nut attaching voltage suppressor (18-gauge red wire) to heat-
sink to 18 in-lb (2.0 N·m). 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 (Figure 3-27, Page 3-33).
2008-2011 Domestic Battery Charger Maintenance and Service Manual
3
Charger Repairs
Page 3-31