PLUG AND RECEPTACLE REPLACEMENT
The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them
for cracks, loose connections, and frayed wiring; they MUST be replaced when worn or damaged. If charger
plug and receptacle show signs of corrosion or are becoming difficult to insert and remove, the receptacle
contacts and plug pins can be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40 ®
brand spray lubricant.
To replace receptacle, see page 17-35.
CHARGER CORD REPLACEMENT
Removal of Charger Cord and Plug:
1. Unplug the AC and DC plugs.
2. Remove the charger cover.
3. Remove the black lead of the charger DC cord from the ammeter by loosening the nut. Support the ter-
minal as the nut is loosened to prevent rotation of the connection.
4. Remove the nut that attaches the red lead of the charger DC cord on the rectifier assembly.
5. Remove the terminal on the blue charger DC cord lead at the relay.
6. Using pliers, squeeze the strain relief bushing and remove the cord set.
Installation of the New Charger Cord and Plug:
1. Insert the leads of the new cord through the hole in the charger base.
2. Attach the red lead of the new cord set to the terminal and torque the nut to 12-15 in.lbs.
(1.4/1.7 N-m).
3. Attach the blue lead of the new cord set to the charger relay (coil) terminal (Figure 19-15).
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 19-16).
1
4
2
3
RED WIRE
TO RECTIFIER
DC CORD
DC CORD
BLACK WIRE
TO AMMETER
DC CORD
BLUE WIRE
TO RELAY
FIGURE 19-16
FIGURE 19-15
19-22
WARNING
• DO NOT ALLOW AMMETER POST TO ROTATE AS NUT IS TIGHTENED. IF IT ROTATES, THE
AMMETER COULD BE DAMAGED.
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