CLUB CAR GOLF CAR CART POWERDRIVE 2 CHARGER REPAIR KIT - Level 6

*Now includes the NEW STYLE Circuit Breaker*, an improvement Club Car/Lester made to minimize early failure of the older style breakers. Replace your chargers new or older style breaker and upgrade to a higher level of reliability.

**Please Notice, this kit also includes a vital part of your charger, the VOLTAGE SUPPRESSOR ASSY, not available in my nearest competitors kits. Should this assembly fail in your charger, the charger will not start its charge cycle.

The LEVEL 6 kit contains a heavier duty rectifier rated at 50 AMPS / 600V for more tolerance to heat, current and also comes with the Sense Lead fuse. 

 

*Fits PowerDrive 2 charger model numbers 22110-**

Included in LEVEL 6 kit :

(1) RELAY                                       (1 ea.)

(2) CIRCUIT BREAKER                     (1 ea.) *** NEW OEM Style Circuit breaker included***

(3) RECTIFIER/DIODE (50 AMP)       (1 ea.)

(4) VOLTAGE SUPPRESSOR ASSY     (1 ea.) wiring harness that includes and replaces special component in charger

(5) SENSE LEAD FUSE                      (1 ea.) 3/8 amp (375 ma) fuse located on cart

(6) THERMAL PASTE  Packet           (1 ea.) absolute must for rectifier, efficiently directs heat from rectifier to charger heatsink

ALSO INCLUDED:  Installation instructions, Component testing procedures, Troubleshooting chart, Charger drawing and wiring diagram, and instructions for boosting your batteries when low.

 

(1) The RELAY may have malfunctioned when no clicking is heard upon plugging into cart or clicking is heard and charging does not proceed. May also cause charger to charge continually ( although, current to batteries should be controlled at a reduced rate.) Usually fails from a worn/burnt/welded closed contacts or control coil short/open condition.

Reference OEM parts #103414901

(2) The CIRCUIT BREAKER shows signs of failing/failure with constant tripping upon plugging charger into cart or during charging. Possible problem when charger is otherwise in good working condition. The circuit breaker is a thermomechanical device and can act as if it is protecting the charger, when in fact it is malfunctioning.

Reference OEM parts #1018287-01 ; #CCX8506

(3) The RECTIFIER will cause fuse link to blow or circuit breaker to trip right as charger is starting the charge cycle or charger will produce no current output or low output, never completing a full charge. Fails from shorted or open/partially open condition. THERMAL PASTE is included.

Reference OEM parts #103517601

(4) The VOLTAGE SUPPRESSOR ASSEMBLY works with your golf carts OBC (onboard computer) to allow the computer to analyze the battery set and if all is good, then supplies a ground to the charger relay, starting the charge cycle. When the suppressor fails in a open or shorted condition, normal charging will not occur. Repeated failure of sense lead fuses is a symptom of a voltage suppressor that has failed in a closed condition.

Reference OEM part #102273601

(5) The SENSE LEAD FUSE protects your golf carts OBC (onboard computer) when the VOLTAGE SUPPRESSOR assy fails in a closed condition. Used on DS models.

Reference OEM part #101863301

I took my experience repairing golf carts and chargers and developed this kit, among others, with my focus on giving the "(D)o (I)t (Y)ourself" cart owner the opportunity to repair their charger, saving the time and expense of a repair shop.

My kits include parts and information, at different "LEVELS" (1 to 6 ), to accomplish the repair, at the least cost, Level 1 being the most common problem. If you have good troubleshooting skills, the best suited kit can be chosen to meet your needs. If you haven't any troubleshooting skills, maybe a LEVEL 5 or 6 kit would be your best choice.

This kit is one of the less expensive methods of eliminating common problems with these chargers, the repair can be accomplished with common tools by most anyone AND, I will offer my help with troubleshooting to ANYONE who needs it.

 

THANKS for looking at my listing