Charger Repairs - Club Car Gasoline Service Manual

2. Attach the red lead of the new cord set to the terminal and tighten the nut to 12-15 in.lbs.(1.4/1.7 N-m).
3. Attach the blue lead of new cord set to the charger relay (coil) terminal (Figure 23-33).
4. Install nut (1) on post of ammeter slightly more than finger tight. While holding the outside nut (1), turn
the inside nut (2) counterclockwise 1/4 of a turn (Figure 23-34).
WARNING
• DO NOT ALLOW AMMETER POST TO ROTATE AS THE NUT IS TIGHTENED. IF IT IS ALLOWED
TO ROTATE, THE AMMETER COULD BE DAMAGED.
5. Put the strain relief bushing on the cord and insert it into the charger base using pliers.
6. Position the charger cover on the base. Starting at the bottom holes, install the attachment screws.
Torque the screws to 10-12 in.lbs. (1.1/1.4 N-m).

CHARGER REPAIRS

WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. ANYONE
DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE
IN GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
WARNINGS STATED IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE
CHARGER.
• ALWAYS UNPLUG THE ELECTRICAL CORDS BEFORE ATTEMPTING ANY REPAIRS TO THE
CHARGER. FIRST UNPLUG THE AC CORD FROM THE OUTLET AND THEN UNPLUG THE DC
CORD FROM THE VEHICLE.
RECTIFIER ASSEMBLY
Removal of Rectifier Assembly (Figures 23-22 and 23-23, Pages 23-33 and 23-34)
1. Remove charger cover.
2. Remove both secondary transformer leads (tan) from the rectifier assembly.
3. Remove the two red wires from the rectifier assembly.
4. Remove the nuts and bolts that secure the rectifier assembly to the case.
Installation of Rectifier Assembly (Figures 23-22 and 23-23, Pages 23-33 and 23-34)
1. Install the nuts and bolts which secure the rectifier assembly to the case. Tighten the bolts to 12-15
in.lbs.(1.4/1.7 N-m).
2. Connect the red wire from the DC cord and the red wire from the charger relay to the center connector
on the rectifier assembly. Torque nut to 12-15 in.lbs. (1.4/1.7 N-m).
3. Connect one of the secondary transformer leads (tan) to the bottom connector of the rectifier assembly.
Torque nut to 12-15 in.lbs. (1.4/1.7 N-m).
4. Connect the other secondary transformer lead (tan) to the top connector of the rectifier assembly.
Torque nut to 12-15 in.lbs. (1.4/1.7 N-m).
5. Replace charger cover.
6. Check charger for proper operation.
23B
E
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