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Service Bulletin #3 - Custom Battery Box

Posted by Power Up on 1/28/2011

Service Bulletin #3


Field Failure: The Power Touch System’s functions erratically. System may also intermittently shut itself down, turning off all lights and equipment.

Unit: New truck in service for 1 to 6 months.

Cause: The “Ground” cable from battery Neg. terminal to the Battery Box, or box bracket, was no longer provided an adequate electrical ground.

Diagnosis: The custom battery box is located in the center of this vehicle. The batteries are grounded to the battery box. The battery box is mounted to the vehicle cross members which are attached to the c-rail frame. The installation was expedited by the use of self-tapping (shoot) screws into pre-painted structural members.  Shoot screws do not develop adequate tension to prevent vibration, moisture, and oxidation from eventually developed inside the assembly until an electrical connection fails. This practice provides a predictably unreliable electrical ground return for the vehicle electrical system.

Field Service: Customer installed a new battery ground cable to the “C” Rail Frame.

Recommended Corrective Action: During installation of Custom Battery Boxes a proper electrical ground, independent of mechanical ground, should be installed.  A ground needs to run from the battery Neg. post to the drivers side c rail through a minimum of a 2awg ground strap.  This gage wire will handle 200 amps of current for the length required.  The cable connectors shall only be crimped with an approved ratcheting crimp tool specifically designed for the size wire and connector used.  And the connection to the frame will be made with a properly tensioned nut and bolt to clean bare metal or to a similarly clean welded stud.

Power Up Products

82 Hardy Drive, Sparks, NV 89431

Questions call (775) 336-2400 Order Toll -Free 1-800-769-3749

Rev. 05/04/10

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