B
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
7
Repair and Service Manual
634756
Aerosol containers of battery terminal protec-
tant must be used with extreme care. Insulate
metal container to prevent can from contacting
battery terminals which could result in an
explosion.
Overfilling batteries may result in electrolyte being
expelled from the battery during the charge cycle.
Expelled electrolyte may cause damage to the vehi-
cle and storage facility.
BATTERY REMOVAL AND INSTALLA-
TION
Tool List
Qty.
Insulated Wrench, 1/2" ................................................ 1
Socket, 1/2" ................................................................. 1
Ratchet ........................................................................ 1
Battery Carrier ............................................................. 1
Torque Wrench (in. lbs.) .............................................. 1
In the following text, there are references to removing/
installing bolts, etc. Additional hardware (nuts, washers
etc.) that are removed must always be installed in their
original position unless otherwise specified. Nonspeci-
fied torques are as shown in the Torque Specifications
table. (See Fig. 2 on page 4.)
Before any electrical service is performed, 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, the Run-Tow/Mainte-
nance switch must be left in the ‘Tow/Maintenance’
position for at least 30 seconds after the circuit is
restored.
Turn vehicle key to ‘OFF’ and remove it from vehicle.
Ensure all optional electrical accessories are turned OFF.
Using an insulated wrench, remove the negative (-) cable
first, the positive (+) cable and then all other cables from
the vehicle batteries. Remove the battery hold down by
removing the hardware and lifting the retainer from the
batteries.
Remove the batteries using a commercial battery carrier.
If the batteries have been cleaned and any acid in the
battery rack area neutralized on a regular basis, corrosion
to the battery racks or surrounding area should not be
present. If any corrosion is found, remove with a putty
knife and wire brush. Wash the area with a solution of
sodium bicarbonate (baking soda) and water and thor-
oughly dry before priming and painting with a corrosion
resistant paint.
Place batteries in the battery rack. Install the battery hold
downs and tighten to 45 - 55 in. lbs. (5 - 6 Nm) torque, to
prevent movement but not tight enough to cause distor-
tion of the battery cases.
Inspect all wires and terminals and clean any corrosion
from the battery terminals or the wire terminals with a
solution of sodium bicarbonate (baking soda) and wire
brush if required.
Aerosol containers of battery terminal protec-
tant must be used with extreme care. Insulate
metal container to prevent can from contacting
battery terminals which could result in an
explosion.
Use care to connect battery cables as shown (Ref. Fig.
Connect the positive (+) battery cable first
, other
battery connecting cables, and then
connect the nega-
tive (-) cable last
. Ensure that all battery terminals are
installed with crimp up. Tighten the battery post hardware
to 90 - 100 in. lbs. (10 - 11 Nm).
Protect the battery termi-
nals and battery cable terminals with a commercially
available protective coating.
Fig. 1 Battery Connections
Negative (-)
Front of Vehicle