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16.
AC INPUT AND DC OUTPUT CORD REPLACEMENT
To replace either the AC input or DC output cord, follow the step-by-step procedures listed
below.
CAUTION: DISCONNECT BOTH AC INPUT AND DC OUTPUT CORDS FROM ALL
POWER SOURCES. POWER IS NOT NEEDED FOR THIS REPLACEMENT.
1. Disconnect the charger’s AC input cord from its outlet and the DC output plug from the
battery receptacle.
2. Remove the Phillips screws that retain the cover and then remove the cover.
3. Disconnect the cords (three wire or two wire) from where they are attached on the inside of
the charger.
The cord strain relief is crimped onto the cord and then snapped into the enclosure. This type of
strain relief if very difficult to remove having three mounting ears which hold it to the enclosure,
thus ensuring that the pullout strength will meet safety requirements.
4. Use a flat bladed screwdriver to pry two of the strain relief mounting ears up. Pry up the top
one and the one closest to the enclosure side as shown in Figure 16A
5. Using a cutting tooling as shown in Figure 16B, cut off the two mounting ears pried up in the
previous step.
6. Pull and wiggle the cord to remove the strain relief from the enclosure and remove the cord
from the charger.
7. Install the new cordset by pushing on the strain relief until it snaps into the enclosure.
8. Reattach the cord wires to the charger: (See wiring diagram)
AC
cord: BLACK
wire
to the relay COM terminal.
WHITE wire to the dual QD terminal on the electronic charge controller.
GREEN wire to the ground connection, which is attached to the enclosure.
DC
cord: BLACK
wire to the ammeter.
WHITE wire to the center lug on the diode assembly.
RED wire to the quick disconnect terminal on the controller wire harness
(see wiring diagram).
9. Replace the cover and tighten the cover screws.
Figure 16A
Figure 16B
