Page 23-46
23B
E
Relay Continuity Test, Continued:
2. With batteries connected, insert the DC plug into a receptacle. Place continuity leads on contact termi-
nals of relay. Tester should show continuity (bulb should light). If tester does not show continuity, the
relay must be replaced.
Ammeter
To check continuity of the ammeter:
1. Disconnect the black wire from the left ammeter post (as viewed from inside the charger).
2. Place the continuity tester alligator clip on one of the ammeter posts.
3. Place the continuity tester probe on the other ammeter post. The tester should show continuity (bulb
should light). If the tester does not show continuity, the ammeter must be replaced.
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 20-35.
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.
FIGURE 23-33
FIGURE 23-34
RED WIRE
TO RECTIFIER
DC CORD
DC CORD
BLACK WIRE
TO AMMETER
DC CORD
BLUE WIRE
TO RELAY
1
4
2
3
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