
Publi s hed: 11-May-2011
General Information - Standard Workshop Practices
Des cript ion and Operat ion
Vehicle in Workshop
W hen working on a vehicl e in the workshop al ways  make sure t hat :
W here practi cable, t he parking brake is  appli ed and t he wheel s are securely chocked to prevent  t he vehi cl e movingforwards  or backwards .W henever pos si ble, t he ignit ion key i s removed before any work is  carried out  on t he vehi cle.If the engine i s  t o be run, t here i s  adequat e vent il ati on, or an extract ion hos e i s  us ed to remove exhaus t  fumes.There i s adequat e room to rais e the vehicle and remove t he wheel s , if neces s ary.Fender covers are al ways  ins tal led i f any work i s to be carri ed out in t he engine compart ment.W here practi cable, t he batt ery i s  dis connected if worki ng on the engi ne, underneath t he vehicle, or if t he vehi cl e i srai sed.
• CAUTIO NS:
 Prior to dis connect ing the bat tery, refer to the El ect ri cal  Secti on of this  manual  - Bat tery dis connect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
 W hen el ect ri c arc wel ding on a vehi cl e, al ways  dis connect  t he generator wi ri ng to prevent  t he pos si bili ty of a s urgeof current  caus i ng damage to the i nternal  component s of the generat or.
If us i ng welding equipment  on t he vehicle, a s uit abl e fire exti nguis her is  readily avail able.
Battery - General
• CAUTIO NS:
 Prior to carrying out  any procedures  which i nvol ve dis connect ing/ or connecti ng the bat tery, refer t o t he ElectricalSect ion of t his  manual - Batt ery di sconnect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
 A di s charged bat tery condit ion may have been caus ed by an electrical short ci rcuit . If t his  condit ion exis t s there wil lbe an apparentl y li ve circuit  on the vehicle even when al l normal circuit s  are s wit ched off. This  can cause arcing when t hejumper cables  are connect ed.
 W hi le it  i s not  recommended that the vehicl e is  jump s t art ed, i t is  recognized t hat thi s may occas ionall y be t he onl ypracti cal  way t o mobi lize a vehi cl e. Prior t o at tempt ing a jump s t art , reference must  be made to the El ect ri cal  Secti on oft hi s  manual - Jump St art ing.
Followi ng jump s tart ing of a dis abl ed vehi cle, the di s charged bat tery mus t be checked for s erviceabili ty and recharged offt he vehi cl e as  s oon as poss ibl e t o avoi d permanent damage.
Do not  rel y on t he generator t o res t ore a di s charged bat tery. For a generat or t o recharge a batt ery, it  woul d take i n exces sof eight hours  cont inuous dri vi ng wi th no addi ti onal loads  placed on t he batt ery.
Always  make s ure that  t he jumper cabl es are adequate for the tas k.Always  make s ure that  t he s lave batt ery i s  of the same vol tage as  t he vehicle bat tery. The bat teries  mus t beconnected i n paral lel.Always  make s ure that  s wit chabl e electric circui ts  are s wi tched off before connecti ng jumper cabl es. This  reducest he ri sk of arci ng occurring when the final connecti on is  made.
Towing the Vehicle
W ARNING: W hen t owing i s neces sary, reference mus t  be made to the Jacki ng, Lift ing and Towing Secti on of thi sManual .
W hen t he vehicle i s  being t owed dock the remote cont rol and s wit ch on the ignit ion. (s t eering l ock releas ed and warni ngli ght s  i ll uminated). Onl y t hen wil l the s t eering, turn s ignal lamps , horn and s t op lamps  be operat ional. Fail ure t o followt hes e i nst ructi ons may res ult  in pers onal injury. It  mus t  be noted that wit h t he engine not running, t he power s t eering andbrake boost er wil l be inoperat ive t herefore, great er effort wil l be needed t o s t eer t he vehicle and apply the brakes .
General Installation Instructions
Component removal
W henever pos si ble, clean component s and the surroundi ng area before removal .
Blank off openings  expos ed by component  removal .Followi ng dis connecti on, s eal fuel, oil  or hydrauli c li nes  i mmediat ely us ing sui table bl anki ng plugs or caps .Seal  open ends of expos ed oil ways  us i ng sui table tapered hardwood pl ugs  or cons pi cuous  pl as t ic pl ugs .Immediat el y a component  i s  removed, place it  i n a sui table contai ner; us e a s eparate cont ai ner for each componentand it s  as s ociat ed part s . 

Publi s hed: 11-May-2011
Battery and Charging System - General Information -
Vehicle Jump (Emergency) Starting - Using another vehicle
• W ARNINGS:
 During normal  us e, bat t eries  emi t expl osi ve hydrogen gas  suffi ci ent  t o cause severe expl os i ons  and capabl e ofcaus ing serious  injury - keep s parks  and naked li ght s  away from the engine compart ment.
 DO NOT at tempt  t o s tart the di s abl ed vehi cl e i f it  is  sus pect ed t hat  t he elect rolyte in the bat tery is  frozen.
 Suit able eye prot ect ion must  be worn when working i n t he vicinit y of t he bat t ery.
 Take care when working near rot at ing parts  of t he engine.
 Prior to att empti ng to st art  t he dis abled vehicle, ens ure t hat the parki ng brake i s appl ied or s uit abl y chock t hewheels . Ens ure that  'P' - PARK - Aut omati c Trans mis s ion or NEUTRAL - Manual  Trans mi ss i on is  s elect ed.
• CAUTIO NS:
 Ens ure t hat al l electrical l oads  are s wi tched OFF pri or to connect ing boos ter cabl es and dis connect boos t er cablespri or to us ing el ect ri cal  equipment .
 Ens ure t hat the bat tery of the DO NOR vehicle is  of 12 volt  capaci ty and that all  electrical loads on t he dis abl edvehi cl e are s wit ched O FF prior t o connecti ng boost er cables .
 Ens ure t hat there is  no phys ical contact  between t he donor and di sabl ed vehi cl es  other than t he boost er cabl es .
• NOTE: Disconnect battery: If t he remote control hands et is  not  functi oning, it  wi ll be neces s ary t o manuall y unlock thevehi cl e us ing t he key.
Carry out the following operation in the sequence given:
1. Connect  one end of the Red (+) boos t er cable to t he pos it ive (+) batt ery terminal of the DISABLED vehicle.2. Connect  t he other end of the Red (+) boos ter cable t o t he posi ti ve (+) batt ery t erminal of t he DONOR vehicle.
3. Connect  one end of the Black (-) boos ter cabl e t o t he Ground (-) bat t ery t ermi nal  of t he DONOR vehi cle.
4. Connect  t he other end of the Bl ack (-) boost er cabl e t o a good eart h point  e.g. unpainted metal  s urface or enginemounti ng at leas t 0.5 m (20.0 i n) from t he batt ery or fuel  l ines  on t he DISABLED vehi cle.
5. Start the engi ne of the DO NOR vehicle and al low it  t o i dl e for a few minut es .6. Start the engi ne of the DISABLED vehicle.
7. All ow engines  of both vehicles  t o i dle for a few mi nut es t hen swi tch off the engine of t he DONO R vehicle.
8. Dis connect t he Black (-)boos t er cable from t he eart h point  of t he PREVIO USLY DISABLED vehi cl e.9. Dis connect t he Black (-)boos t er cable from t he batt ery of t he DONO R vehicle.
10. Dis connect the Red (+) boos t er cable from t he batt ery of t he DONOR vehi cl e.
11. Dis connect the Red (+) boos t er cable from t he batt ery of t he PREVIOUSLY DISABLED vehi cl e.
Vehicle Jump (Emergency) Starting - Using a Slave Battery/Starting Aid
• W ARNINGS:
 During normal  us e, bat t eries  emi t expl osi ve hydrogen gas  suffi ci ent  t o cause severe expl os i ons  and capabl e ofcaus ing serious  injury - keep s parks  and naked li ght s  away from the engine compart ment.
 DO NOT at tempt  t o s tart the di s abl ed vehi cl e i f it  is  sus pect ed t hat  t he elect rolyte in the bat tery is  frozen.
 Suit able eye prot ect ion must  be worn when working i n t he vicinit y of t he bat t ery.
 Take care when working near rot at ing parts  of t he engine.
 Prior to att empti ng to st art  t he dis abled vehicle, ens ure t hat the parki ng brake i s appl ied or s uit abl y chock t hewheels . Ens ure that  'P' - PARK - Aut omati c Trans mis s ion or NEUTRAL - Manual  Trans mi ss i on is  s elect ed.
• CAUTIO NS:
 Ens ure t hat al l electrical l oads  are s wi tched OFF pri or to connect ing boos ter cabl es and dis connect boos t er cablespri or to us ing el ect ri cal  equipment .
 Ens ure t hat the s l ave bat tery/s tarti ng aid are of 12 volt  capacit y and t hat  al l elect rical  l oads  on the di sabl ed vehi cl eare swi tched OFF prior t o connecti ng boos t er cables . 

Due t o t he high depth of di scharge a deal er demons trati on vehi cl e batt ery may experience, bat teri es t hat  are fi tt ed t ovehi cl es us ed as deal er demons trati on vehi cl es mus t be connected t o a power s upply / charger capable of deli vering 50Amps  or more whil st  the vehicle is  being demons trated and t he engine i s not running. Thi s  wi ll prevent the bat tery frombeing damaged from "energy t hroughput  " wear out during a demons t rat ion.
Software Reflash, SDD work or Ig nition On related Workshop Activities.
Due t o t he high elect rical current  demand and high dept h of Dis charge that  can occur duri ng vehi cl e s oft ware re-flas hact ivi ti es , SDD work or igni ti on on rel at ed work in the workshop, vehi cl es that  are undergoi ng s uch act ivit ies  MUST havet he elect rical  s ys tem on t he vehi cl e s upported wi th a power supply / charger / vehicle maintai ner capabl e of deliveri ng 50Amps  or more.
Jump  Starting New vehicles Before They Have Been Delivered to the Customer.
It is  t he dealer / ret ailers  res ponsi bili ty to ens ure the bat tery is  not  al lowed t o go flat by fol lowi ng the i nst ruct ionsand process es  defi ned in this  manual .However i f ci rcums tances dictat e t hat  a new vehi cl e mus t  be jump s t arted due to a flat bat t ery whil s t the vehicle isin the dealer / retail ers  care, t he batt ery on this  vehi cl e mus t be repl aced wi th a new one prior to del ivery to thecus t omer at the dealer / retail ers  l iabil it y.The vehi cl e s houl d als o undergo inves t igati on as  t o why t he batt ery went  flat.Do not  connect the jump s t art ing cable t o t he negat ive (-) terminal of the bat tery. Al ways  connect  t o t herecommended eart hing point . As defined i n t he owners  handbook or s ervice document ation for t hat vehi cl e.
Jump  Starting or Boost Charging  Vehicles in Service
Do not  connect the jump s t art ing cable t o t he negat ive (-) terminal of the bat tery. Al ways  connect  t o t he recommendedeart hing point . As defined i n t he owners  handbook or s ervice document ati on for t hat vehi cl e.
Charging AG M Batteries
AGM bat teries  mus t  not be charged wit h volt ages  above 14.8 Vol ts . Doing so wil l damage t hem.
Testing AGM Batteries
Midt ronics  393, 394, 493 and 494 t es ters  are not  capabl e of tes ti ng AGM bat teries . Doing s o can give an incorrect res ult .
W hen i t is  necess ary to tes t an AGM bat tery us e t he Midt ronics  EXP1080 tes ter or t he GR1 Diagnost ics  Charger.
3. EQUIPMENT (MINIMUM STANDARD) (pictures are for illustration only)
Tracti on Batt ery Charger (or si mil ar st and-alone charger)
Midt ronics  EXP1080 Hand-Held Tes ter