P 2 / 3
1) Turn Charger upside down.
2) Remove four Caps 13 and BT4x20 Tapping screws.
Note: Be careful not to lose Caps 13.
3) Turn Charger over again and remove Charger case complete. (Fig. 1)
4) When replacing Terminal unit, disconnect Connector CN1 and CN2 from Charging circuit and install the new Terminal
unit carefully as follows: (Fig. 2)
Do not pinch Lead wires between the walls of Charger case cover and Charger case complete.
Route Lead wires with Lead wire holder (indicated by gray color in Fig. 2) and Clip.
Connect Connector CN1 and CN2 to Charging circuit securely.
Put the both ends of Compression spring 4 (Part No. 233194-8) to each boss of Charger case cover and Terminal unit
and insert Three pins of Terminal unit into holes of Charger case cover.
Fig. 1 Fig. 2
Fig. 3 Fig. 4
Charger case complete
Charger case cover
Walls of Charger case cover
Lead wire holder
Boss for
Compression
spring 4
Pin of Terminal unit
Compression spring 4
(233194-8)
Clip
Connector CN2
Charging circuit
Connector CN1
Repair
5) When replacing Terminal cover;
(1) Remove BT3x10 Tapping screw behind Charger case cover.
(2) Separate Terminal cover from Charger case complete carefully so as not to lose two Compression springs 4
(Part No. 231474-6) behind Terminal cover.
(3) Compressing Compression springs 4 in new Terminal cover, fit the oval wall of Charger case complete into the oval
wall of Terminal cover and secure Terminal cover to Charger case complete by tightening BT3x10 Tapping screw.
(Figs. 3 and 4)
Note: 1) The tightening torque has to be 0.5N.m.
2) Use two different Compression springs 4 (233194-8 and 231474-6) for their appropriate positions.
BT3x10 Tapping
screw
Oval wall of
Charger case
complete
Terminal cover
Terminal cover
Compression
spring 4
(231474-6)
Oval wall of
Terminal cover
Charger case
complete
Boss of charger
case complete
Boss of charge
case complete
Compression
spring 4 (231474-6)
[1] Replacing Terminal unit and Terminal cover
