B
ELECTRICAL
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
47
Repair and Service Manual
10002660
VOLTAGE TESTING FOR BATTERIES
Hydrogen gas formed during bat-
tery charging is explosive.
Avoid any electrical spark or open
flame near battery.
NOTICE: If the temperature of the battery or the
ambient temperature is below 60° F (15.55° C), the
capacity of the battery will be reduced, and it will
require more time to charge.
Voltage on a cold battery increases faster, therefore
reducing the charging rate.
Fully charge new batteries or batteries that have been in
storage before testing or installing in vehicle.
Do not over charge battery.
Use a Digital Volt Ohm Meter (DVOM) to check the bat-
tery.
Attach the negative (-) lead of the DVOM to the ground
terminal of the battery. Attach the positive (+) lead to the
positive battery terminal. The voltage reading obtained
should be 12 volts or above. If the reading is below 12
volts, the battery needs to be charged or replaced.
MAIN HARNESS
Power Supply
Tool List
Qty.
DVOM.......................................................................... 1
1.
Check for loose or bare wires.
2.
Check for loose wires at each terminal connection
and for worn insulation or bare wires touching the
frame.
Bare wires can cause a short-cir-
cuit.
NOTICE: If any DVOM readings indicate a faulty
wire, check the condition of the terminals and wire
junction. A faulty wire must be replaced. (See Faulty
Wire Replacement on page 48)
3.
Check the condition of the 72V batteries set.
a. Check for adequate battery volts (nominal 12
VDC) by setting the DVOM to 30 VDC range and
place the red probe (+) on the battery post with
the white (WHT) wire attached.
b. Place the black probe (-) on the battery post with
the black (BLK) wire attached.
c. A reading of 11 VDC or greater indicates ade-
quate battery condition.
d. No reading indicates:
•
a poor connection between the probes and
the battery terminals or
•
a faulty DVOM
e. A voltage reading below 11 volts indicates poor
battery condition and the vehicle should be
recharged before proceeding with the test.
Fig. 5 72V Battery Set Connections
NOTICE: Due to the resistance of the wires involved
within the harness, voltage readings can be slightly
lower than battery voltage. A reading of 1 volt below
battery voltage is acceptable.
4.
Check the power wire.
a. Attach the black probe (-) to the battery post with
the black wire attached.
b. Attach the red probe (+) to the power (white) wire
terminal at the fuse block.
c. A reading of battery voltage indicates that the
power wire is in good condition.
NOTICE: The power wire supplies power to the
entire fuse block.
5.
Check the fuse (Ref. Fig. 6).
a. Place the red probe (+) to each wire terminal on
the fuse block.
b. A reading of battery voltage indicates that the
fuse is in good condition.
c. No reading indicates a faulty fuse; replace with a
good fuse of the same amperage rating.
NEG
POS
NEG
POS
NEG
POS
NEG
POS
NEG
POS
NEG
POS
To Solenoid
To
Controller B-
Disconnect BL- cable
