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SERVICE/REPAIR
RECOMMENDED BATTERY SPECIFICATIONS
1. Size: Group 31, 900-1200 CCA, AGM
2. Use battery with 3/8" threaded studs.
3. A high quality battery emits fewer gases as it recharges. Using a high quality battery will extend charger and
wiring life. Battery acid and petroleum resistant wiring is used in this unit. Battery fluid level must be checked
every 30 to 45 days.
BATTERY REPLACEMENT (HEAVY TRUCK HT1224)
See Figure 1
REMOVING OLD BATTERIES
1. Remove front top panel by removing (8) #8 Phillips screws securing panel. Remove bottom front panel by
removing (3) top and (3) bottom #8 Phillips screws (2 middle side screws are false screws –DO NOT try to
remove).
2. Disconnect cables and wires from batteries. Label for easier reconnection. Move cables out of way.
3. Remove the nut from the left side of the AMPS gauge and disconnect red wire.
4. Disconnect the two fast on connectors of the power cord wires from charger. Remove green power cord wire
from charger by removing 6-32 nut.
5. Remove charger from unit by removing top (5) #8 Phillips screws from back panel (3 bottom screws are false
screws – DO NOT try to remove). Lift out panel and charger. Set aside.
6. Remove front and rear hold-down bars by removing (4) 1/4-20 bolts with 7/16" sockets or wrenches. Set aside
for later use. DO NOT touch hold-down across battery terminals, as arcing will occur.
7. Remove upper rear battery by lifting battery up, turning and sliding it out rear opening of unit.
8. Remove lower front battery by lifting battery up, turning and sliding it out rear opening of unit.
INSTALLING NEW BATTERIES
1. Slide first battery in through rear opening, turning battery so that its vent faces the front of unit. Then set
battery on lower platform of battery stand.
2. Slide second battery in through rear opening, turning battery so that its vent faces the front of unit. Then set
battery on upper platform of battery stand.
3. Install rear hold-downs, then front hold-downs, using (4) 1/4-20 bolts. DO NOT touch hold-downs across
battery terminals, as arcing will occur.
4. Insert back plate with charger onto the unit and re-fasten the (5) #8 x 1/2" screws securing it into place.
5. Connect red wire from Charger #1 (upper charger) to the AMPS gauge, replace the nut and tighten.
6. To left side of rear battery (Battery #2, NEG Terminal) connect the black wire from Charger #2 (lower
charger), Cable from Negative side of 12 Volt quick connect, and Negative jumper cable with attached black
wire from the right side of VOLTS gauge. Apply nut and tighten.
7. To right side of rear battery (Battery #2, POS Terminal) connect the red wire from Charger #2 (lower charger)
and cable from Positive side of Common Quick Connect with handle. Apply nut and tighten.
8. To left side of front battery (Battery #1, NEG Terminal) connect the black wire from Charger #1 (upper
charger) and cable from Negative side of Common Quick Connect with handle. Apply nut and tighten.
9. To right side front battery (Battery #1, POS Terminal) connect the cable from the Positive side of the 12 Volt
quick connect and Positive Jumper Cable with attached red wire from the right side of AMPS gauge. Apply
nut and tighten.
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