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OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Remove battery hold downs and cables. Lift out batteries
with a commercially available lifting device.
If the batteries have been cleaned and any acid in the
battery rack area neutralized as recommended, no corro-
sion 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.
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death, extreme care must be used with aerosol con-
tainers 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.
28 on page 22). Tighten the battery post hardware to 50 -
70 in. lbs. (6 - 8 Nm) torque
and battery wire terminals with a commercially available
protective coating.
Front of Vehicle
Ref Bat 1
Fig. 28 Battery Connections
Prolonged Storage
Battery charger, controller and other
electronic devices need to be discon-
nected since they will contribute to the premature discharge of
batteries.
Page 22
To prevent battery explo-
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sion that could result in
severe personal injury or
Protect the battery terminals
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Owner's Manual and Service Guide
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
can be used to determine the specific gravity and there-
fore the state of charge of a battery.
In winter conditions, the battery must be fully charged to
prevent the possibility of freezing (Ref Fig. 29 on page
23). A fully charged battery will not freeze in tempera-
tures above -75° F (-60° C). Although the chemical reac-
tion is slowed in cold temperatures, the battery must be
stored fully charged, and disconnected from any circuit
that could discharge the battery. For PDS vehicles, the
controller should be disconnected from the batteries by
setting the Run-Tow/Maintenance switch, located under
the passenger seat, to the 'TOW/MAINTENANCE' posi-
tion. For portable chargers, disconnect the charging plug
from the vehicle receptacle. For on-board chargers, dis-
connect the charging harness from the batteries. The
batteries must be cleaned and all deposits neutralized
and removed from the battery case to prevent self dis-
charge. The batteries should be tested or recharged at
thirty day minimum intervals.
BATTERY CHARGING
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The battery charger is designed to fully charge the bat-
tery set. If the batteries are severely deep cycled, some
automatic battery chargers contain an electronic module
that may not activate and the battery charger will not
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function. Automatic chargers will determine the correct
duration of charge to the battery set and will shut off
when the battery set is fully charged. Always refer to the
instructions of the specific charger used.
Before charging, the following should be observed:
component damage.
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The electrolyte level in all cells must be at the rec-
ommended level and cover the plates.
Do not overfill batteries. The charging
cycle will expel electrolyte and result in
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