B
BATTERIES AND BATTERY CHARGER
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
15
Repair and Service Manual
10002660
Use insulated wrenches to prevent
the possibility of a dropped wrench
from ‘shorting out’ a battery, which
could result in an explosion and severe personal
injury or death.
Make sure that the key switch is in the OFF position and
remove the key from vehicle. Make sure all electrical
accessories are deactivated.
1.
Remove the negative (B-) cable.
2.
Remove the positive (B+) cable.
3.
Remove the nuts (6) and hold down bolts (4) from
the battery hold downs (2) and battery bracket (1).
4.
Remove the batteries (3) using a battery carrier (Ref.
5.
Remove all corrosion from terminals and hardware
with a putty knife and wire brush.
6.
Wash the area with a solution of sodium bicarbonate
(baking soda) and water and thoroughly dry.
7.
Apply corrosion resistant paint battery racks and sur-
rounding area.
Battery Installation
1.
Place the batteries (3) in the battery racks.
2.
Install the battery hold downs (2) and battery bracket
(1) with hold down bolts (4).
3.
Tighten the lock nuts (6) to torque specified below,
tight enough to prevent movement of the battery but
not tight enough to cause distortion of the battery
cases.
4.
Inspect all wires and terminals.
5.
Clean any corrosion from the battery terminals or the
wire terminals with a solution of sodium bicarbonate
(baking soda) and brush.
6.
Connect the battery wires as shown (Ref. Fig. 2). Be
sure that all battery terminals are installed with crimp
upward.
7.
Tighten the battery terminal hardware to torque value
specified below.
Do not overtighten the battery ter-
minal clamps. This will cause a
“mushroom” effect on the battery
post, preventing the terminal nut from being prop-
erly tightened. Protect the battery terminals and bat-
tery wire terminals with a commercially available
protective coating.
Aerosol containers of battery pro-
tector spray must be used with
extreme care. Insulate metal con-
tainer to prevent can from contacting battery termi-
nals which could result in an explosion.
After installing batteries, coat terminals with commercially
available terminal protector spray.
Fig. 2 Battery Connections
BATTERY MAINTENANCE
Tool List
Qty.
Insulated Wrench, 9/16”...............................................1
Battery Carrier .............................................................1
Hydrometer ..................................................................1
Battery Maintenance Kit P/N 25587G01......................1
Battery Protective Spray ..............................................1
Torque Wrench, in.lbs ..................................................1
Insulated Socket, 9/16” ................................................1
Terminal Spreader .......................................................1
Ratchet ........................................................................1
At Each Charging Cycle
Before charging the batteries, inspect the battery charger
connector and vehicle receptacle housing for dirt or
debris. Clean with compressed air if necessary.
Charge the batteries after each day of use.
Item
Torque Specification
Lock Nut (6)
16 - 19 ft. lbs. (22 - 26 Nm)
Battery Terminal
Hardware
90 - 110 in. lbs. (10 - 12 Nm)
NEG
POS
NEG
POS
NEG
POS
NEG
POS
NEG
POS
NEG
POS
To Solenoid
To Controller B-
“ + “ Terminal
“ - “ Terminal
