Club Car 1995 Golf Car Maintenance Service Supplement page 86

Removal of the Transformer (Figures 19-4 and 19-5, Page 19-7):
1. Remove the charger cover.
2. Disconnect the tan primary coil lead from the charger relay, then disconnect the white wire from the AC
cord.
3. Disconnect the secondary transformer leads from the rectifier assembly.
4. Disconnect the secondary transformer leads from the fuse assembly.
5. Remove the four bolts and nuts that mount the transformer to the case and remove the transformer.
Installation of the Transformer (Figures 19-4 and 19-5, Page 19-7):
1. Install the transformer with secondary coil to the rear of the charger case. Torque the four bolts and nuts
to 25-30 in.lbs. (2.8/3.4 N-m).
2. Connect one secondary transformer lead (tan) to the top of the rectifier assembly. Torque nut to 12-15
in.lbs. (1.4/1.7 N-m).
3. Connect the other secondary transformer lead (tan) to the bottom terminal of the rectifier assembly.
Torque nut to 12-15 in.lbs. (1.4/1.7 N-m).
4. Connect one secondary transformer lead (black) to one terminal of the fuse assembly. Torque nut to 20-
24 in.lbs. (2.3/2.7 N-m).
5. Connect the other secondary transformer lead (black) to the remaining terminal of the fuse assembly.
Torque nut to 20-24 in.lbs. (2.3/2.7 N-m).
6. Connect the tan primary lead to the charger relay.
7. Connect the other primary lead to the white wire from the AC cord.
8. Replace charger cover.
9. Check charger for proper operation.
AMMETER (FIGURE 19-17):
Removal of Ammeter
1. Remove charger cover.
2. Disconnect black wire from the DC cord (5), and the buss bar (3) from the ammeter (Figure 19-17).
3. Remove the two nuts (2) that secure the ammeter to the charger face.
4. Remove the ammeter from the face of the charger.
Installation of Ammeter:
1. Place the ammeter in position in the charger face.
2. Install the washers and nuts and tighten until ammeter is firmly secured.
3. Connect the black wire of the DC cord to the left (when viewed from inside the charger) post of the
ammeter.
4. Connect the buss bar from the fuse link to the right post of the ammeter, placing washers on both sides
of the buss bar.
5. Thread nuts onto both posts of the ammeter until just past finger tight. While holding the outside nut,
turn the inside nut counterclockwise 1/4 of a turn.
6. Replace the charger cover.
7. Plug the charger into vehicle and check to be sure that ammeter is operating properly.
19-24