Interlock Repair on G8

[MudHog]

I fixed my interlock problem today and figured I would write a dedicated writeup on it. Very simple, so I will simply post pictures and caption each picture. I've seen wiring diagrams on G8 and G9 models and both have the interlock setup. I'm not certain which other models have this, so mayone someone else can chime in as to what models are prone to this interlock failure.


This is what the insides of the charger plug looks like and the interlock can be seen on the left piece. The gold disc is the piece that closes the circuit between the two small red wires. The small spring can be seen in the center of the gold disc. On the right half and between the two charger contacts is a small hole and a larger hole right below the small hole. The larger hole is where the interlock spring rests in and this hole is tapered which is not good for a flat base spring to bind up on.



In this picture you can see the small panhead bolt I used to fix my problem. A new spring could have been used, but the bolt fixed the problem and corrected the tapered hole for the spring to rest in. A flat tapered head bolt would work just as good, but the panhead is what I had laying around the shop.



In this picture you can see where the bolt is placed.



Bolt the two halves back together and use a volt meter to check voltage across the small wires. You should have full battery pack voltage on the small red wire.

[apc237]

nice i am going to try the same repair on mine