Charging the Batteries
Service Interval:
Before each use or daily
A charger is supplied with the machine. Always keep the
charger in a dry location. For maximum battery life, charge
the batteries whenever you are not using the machine.
Depending on how discharged the batteries are, it may take
up to 16 hours to charge the batteries to full capacity.
Important:
Lead-acid batteries do not develop a
charge memory and do not need to be fully discharged
before charging them.
Fully discharging the batteries
may damage them. Charge the batteries any time the
machine is not in use.
WARNING
Charging the battery produces gasses that can
explode.
Never smoke near the batteries and keep sparks
and flames away from them.
1.
Position the machine in a well-ventilated area near a
suitable power outlet.
2.
Check the electrolyte level of the batteries.
Note:
Add distilled water to the batteries as needed;
refer to
Adding Distilled Water to the Batteries. (page
.
3.
Connect the charger cord to the charging receptacle on
the machine (located on the panel between the seats).
Note:
Ensure that the charger voltage setting matches
the voltage at the power outlet being used.
4.
Plug the charger power cord into the power outlet.
Note:
While the batteries are charging, the green light
on the charger will blink on and off. When the batteries
are fully charged, the green light stops blinking and
stays on.
5.
Disconnect the cord from the power outlet.
6.
Disconnect the charger from the machine.
Important:
Do not carry the charger on the machine.
Excessive or prolonged jarring may damage it.
Adding Distilled Water to the Batteries.
Service Interval:
Every 25 hours/Every 2 weeks (whichever
comes first)
Use only clean, distilled water to fill the batteries.
1.
Raise the cargo bed, turn the key off, and remove it.
2.
Remove the filler caps from each battery.
3.
If the electrolyte is not over the top of the plates in
each battery cell, add just enough distilled water to
cover the plates.
4.
Replace the filler caps on all batteries.
5.
Charge the batteries until a full charge is achieved; refer
to
Charging the Batteries (page 33)
.
6.
Once the batteries are fully charged, remove the filler
caps from each battery.
7.
Add just enough distilled water to bring the electrolyte
level to 3 mm (1/8 inch) below the bottom of each
fill well (
).
Figure 37
1.
Battery plates
3.
Electrolyte level
2.
Filler cap
4.
Battery terminal
Important:
Do not overfill the battery. Electrolyte
will overflow onto other parts of the machine and
severe corrosion and deterioration may result.
Also, overfilling the battery will reduce the life of
the battery.
8.
Replace the filler caps on all batteries.
Changing the Batteries
When the machine begins to lose operating range or when
the length of time to discharge or charge the battery is
significantly reduced, the batteries are probably wearing and
losing their ability to hold a charge. Take the machine to an
Authorized Service Dealer and have them test the batteries
to determine whether the batteries need to be replaced. The
dealer can then replace the batteries for you. If you wish to
replace the batteries yourself, use the following procedures:
Disconnecting the Batteries
1.
Raise the cargo bed, turn the K
EY
S
WITCH
to the O
FF
position, and remove the key.
2.
Disconnect the main negative-battery cable (black) that
connects the bank of batteries to the ground point of
the machine (
Note:
The main battery cables are long when
compared to battery-interconnect cables.
33
