How to Replace a Battery Charger Rectifier with the RR-50 Repair Kit

A failing rectifier can turn a reliable battery charger into a frustrating piece of equipment, but replacing it doesn’t have to be complicated.

In this video, we walk through replacing a rectifier diode assembly using the PLP Battery RR-50 repair kit. This simple upgrade improves durability and increases current handling capacity from the standard OEM setup. Whether you’re repairing a Shoe Maker charger or another compatible unit, this step-by-step guide shows how to restore charger performance in just a few minutes.

Video Key Takeaways

• Learn what a rectifier does in a battery charger

• Understand why rectifier diodes fail over time

• See how the RR50 kit upgrades standard 25-amp diodes to 50-amp diodes

• Follow the complete installation process from removal to testing

• Learn why thermal grease is essential for heat management

• Discover how to properly orient the diode assembly for correct polarity

• Pick up troubleshooting tips to avoid common installation mistakes

Inside the RR50 Rectifier Replacement Process

Repair begins by removing the original rectifier assembly from the charger’s heat sink plate. Most OEM assemblies are riveted in place, so the first step is to carefully drill out the rivets and remove the damaged diode assembly.

Once removed, thoroughly clean the heat sink plate to remove old thermal grease and debris. This is an important step because proper heat transfer helps prevent future diode failure.

Prepare the mounting hole using a 9/64-inch or 5/32-inch drill bit. This slight enlargement allows the new nut-and-bolt mounting hardware included in the RR50 kit to fit properly.

One of the most critical parts of the installation is diode orientation. The RR50 diodes must be installed with the ring side (cathode) facing downward to ensure proper polarity and current flow. The replacement assembly also includes an alignment pin that helps position the unit correctly on the mounting plate.

Before installation, thermal grease should be applied to the bottom of each diode to improve heat dissipation. Then secure the new assembly using the included hardware and spring tension system, which helps maintain consistent pressure against the heat sink.

After installation, test the rectifier with a multimeter to verify proper diode operation and orientation. A successful test confirms the charger is ready to return to service.

Why Upgrade to the RR50 Repair Kit?

Unlike many OEM rectifiers that use 25 amp diodes, the RR50 repair kit upgrades the charger to 50 amp diodes. This provides:

• Better durability under heavy use

• Improved tolerance to electrical overloads

• Longer component lifespan

• More reliable charger performance

For technicians and DIY repairers alike, this upgrade offers a fast and cost-effective way to improve older battery chargers without replacing the entire unit.

Ready to Repair Your Charger?

Replacing a rectifier with the RR50 repair kit is a quick repair that can dramatically improve battery charger performance and reliability. With proper installation, correct diode orientation, and good thermal management, your charger can continue operating for years to come.

For replacement parts, repair kits, or additional support, contact PLP Battery Supply or call 800-642-3451.