Page C-4
Repair and Service Manual
B
BATTERIES AND CHARGING
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Battery Replacement
Before any electrical service is performed on PDS model
vehicles, the Run-Tow/Maintenance switch must be
placed in the ‘Tow/Maintenance’ position.
If a power wire (battery, motor or controller) is dis-
connected for any reason on the PDS model vehicle,
the Run-Tow/Maintenance switch must be left in the
‘Tow/Maintenance’ position for at least 30 seconds
after the circuit is restored.
Remove battery hold downs and cables. Lift out batter-
ies with a commercially available lifting device.
If the batteries have been cleaned and any acid in the
battery rack area neutralized as recommended, no cor-
rosion to the battery racks or surrounding area should
be present. Any corrosion found should be immediately
removed with a putty knife and a wire brush. The area
should be washed with a solution of sodium bicarbonate
(baking soda) and water and thoroughly dried before
priming and painting with a corrosion resistant paint.
The batteries should be placed into the battery racks
and the battery hold downs tightened to 45 - 55 in. lbs.
(5 - 6 Nm) torque, to prevent movement but not tight
enough to cause distortion of the battery cases.
Inspect all wires and terminals. Clean any corrosion
from the battery terminals or the wire terminals with a
solution of sodium bicarbonate (baking soda) and brush
clean if required.
To prevent battery explosion that could result
in severe personal injury or death, extreme
care must be used with aerosol containers of
battery terminal protectant. Insulate the metal
container to prevent the metal can from con-
tacting battery terminals which could result in
an explosion.
Use care to connect the battery wires as shown (Ref.
Fig. 5). Ensure that all battery terminals are installed
crimp up. Tighten the battery post hardware to 90 - 110
in. lbs. (10 - 12.5 Nm) torque
.
Protect the battery termi-
nals and battery wire terminals with a commercially
available protective coating.
Fig. 5 Battery Connections
Prolonged Storage
Battery charger and controller and other electronic
devices need to be disconnected since they will contrib-
ute to the premature discharge of batteries.
During periods of storage, the batteries will need atten-
tion to keep them maintained and prevent discharge.
In high temperatures the chemical reaction is faster,
while low temperatures cause the chemical reaction to
slow down. A vehicle that is stored at 90° F (32° C) will
lose .002 of specific gravity each day. If a fully charged
battery has a specific gravity of 1.275, and the battery is
allowed to sit unused, it will become partially discharged.
When it reaches 1.240, which it will do in less than
twenty days, it should be recharged. If a battery is left in
a discharged state, sulfating takes place on and within
the plates. This condition is not reversible and will cause
permanent damage to the battery. In order to prevent
damage, the battery should be recharged. A hydrometer
(P/N 50900-G1) can be used to determine the specific
gravity and therefore the state of charge of a battery.
In winter conditions, the battery must be fully charged to
prevent the possibility of freezing (Ref. Fig. 6). A fully
charged battery will not freeze in temperatures above
-75° F (-60° C). Although the chemical reaction is
slowed in cold temperatures, the battery must be stored
fully charged, and disconnected from any circuit that
could discharge the battery. For portable chargers, dis-
connect the charging plug from the vehicle receptacle.
For on-board chargers, disconnect the charging harness
from the batteries. The batteries must be cleaned and all
deposits neutralized and removed from the battery case
+
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+
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+
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+
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+
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Front of Vehicle
BL+ to
Solenoid
+
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+
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To
Charger
BL- to B-
on ESC
