Installation

Battery Safety

  1. Never smoke or produce a spark in the battery area.
  2. When performing battery maintenance wear safety glasses, rubber gloves and protective clothing.
  3. When using a hydrometer avoid letting the rubber tube shake as this can cause drops of electrolyte to splash onto your clothing or into your eyes. If you should get battery acid in your eyes flush with clear water for 15 minutes and seek medical attention. Do not use the neutralizing agent in your eyes. Store your hydrometer in a clean dry place.
  4. Do Not Overfill Excessive water may spill out while battery is charging.
  5. Do not let foreign objects enter the cells.

Prior to installing batteries acquire the following safety items

  1. Safety glasses or face shield
  2. Acid resistant apron
  3. Insulated 7/16 wrench
  4. Insulated ratchet with 7/16 socket
  5. 1 gal neutralizing agent ( 1# baking soda to gal. water, mix this solution thoroughly)
  6. Rubber Gloves

Note: Wrapping your tools with several layers of electrical tape will reduce the hazard of shorting from cell to cell. You should also remove any jewelry that may be at risk of shorting.

  • Step 1  Inspect the battery and steel can for evidence of damage, if damage has occurred file a claim with the carrier immediately. If you see liquid on the top of the cells pour some neutralizing agent in to a small container and apply with a clean paint brush.

Be extra careful not to get any of this agent into the cell. Apply this agent to the terminals as well as the cell tops then rinse with clear water and wipe dry.

  • Step 2  Remove the can lid by tapping one hinge back into the lid hinge: or remove the internal hex-head bolts.
  • Step 3  Remove the buss bars.
  • Step 4  Connect the cell lifting strap into the holes of the terminals that are inline with the round post that protrude from the case. Lift the cells out of the steel can. Removing the first cell may be harder than the remaining the cells. If you find the first cell very hard to remove, try another cell or lubricate the cell with a soapy water solution. DO NOT allow this solution to enter the cell.

Caution: These cells can be extremely heavy, a come-along or block and tackle may be needed to do the lifting. Do not try lifting these cells by yourself serious injury could occur.

Caution: The weight inside the plastic cells will cause the sides to bulge when removed from the can, this is normal, use caution when handling the cells. Any pressure on the sides will cause the cells to “breathe” and can release small droplets of electrolyte in the area of the cap. Placing a rag over the vent cap will reduce this hazard.

Note: As you remove the cells from the can you may notice the electrolyte level is very low. DO NOT add water to the cells, this condition is normal. As soon as the battery is reassembled, charge the battery @ 2% of it’s rated capacity, after approximately 2 hours the electrolyte level will return to normal. If the electrolyte level does not rise as expected contact your dealer.

  • Step 5  Neutralize the sides of the cells and the steel can. Rinse and dry thoroughly.
  • Step 6  Move the steel can to the desired location.
  • Step 7  Install the cells back into the can using the diagram to ensure the cells are correctly installed. The cells must be completely seated in the can to properly install the cell interconnects. All plastic spacers must be reinstalled when the battery is reassembled.
  • Step 8  Referring to the diagrams install the nuts and bolts in the exact pattern as shown. Torque all bolts to 40 in. lbs.
  • Step 9  Install the lid by taping the hinge pin back into the can hole. When you install the lid you have a choice of where the hinges are located. Some lid hinges use a internal hex head bolt, use an “Allen wrench” to remove and replace the lid.

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