IK0800382 - ProStar Battery Cable Routing - 12654

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SB-10045780-1045

Countries:

CANADA,
Document
IK0800382
UNITED STATES ID:

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Internal Attachable

Revision:

0

Major
System:

ELECTRICAL
SYSTEM

Created:

7/30/2012

Current
Language:

English

Last
Modified:

8/6/2012

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NONE

Author:

Lindsey
Christopher

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102
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Title: ProStar Battery Cable Routing - 12654
Applies To: Garland-Built ProStar113" and 8600 LSM
DESCRIPTION
On Garland-built ProStar® 113” with left-side battery box, or 8600 with left-side BOC battery box, the battery
cables may route too close to the spring hanger shackle bolt.

TOOLS REQUIRED
Description

Tool Number / Type

Socket Wrench

7/16 in.

Diagonal Cutting Pliers

-

PARTS INFORMATION
Part Number

Description

Quantity

3807534C1

Mounting bracket

1

3626607C1

Cable straps

2

Obtain locally

5/8 in. x 1 ½ bolt

1

Obtain locally

5/8 in. nut

1

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IK0800382 - ProStar Battery Cable Routing - 12654

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Obtain locally

5/8 in. lock washer

1

2041341C1

Saddle

1

Obtain locally

¼ x 1 ¼ in. UNC bolt

1

Obtain locally

¼ in. UNC nut

1

Obtain locally

¼ in. lock washer

1

R3X9BR5495

Positive cable*

1

R4X6BR1465

Positive cable*

1

K3X9419320

Negative cable*

1

K3X6742390

Negative cable*

1

*NOTE: If cables are not available, produce cables locally.
STANDARD REPAIR TIME
Operation Number

Description

Time

A08T1

Inspect and re-route
cables

0.2 hr.

A08T2

Inspect, add mounting
bracket, and re-route
cables

0.4 hr.

WORK INSTRUCTIONS
WARNING!
Park vehicle on hard flat surface, turn the engine off, set the parking brake, and block
the wheels to prevent the vehicle from moving in both directions. Failure to do so may
result in property damage, personal injury, and/or death.
WARNING!
If the vehicle must be raised, do not work under the vehicle supported only by jacks.
Jacks can slip or fall over, potentially resulting in property damage, personal injury,
and/or death.
WARNING!
Always wear safe eye protection when performing vehicle maintenance. Failure to do so
may result in serious eye injury.
WARNING!
Keep flames or sparks away from vehicle and do not smoke while servicing the

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IK0800382 - ProStar Battery Cable Routing - 12654

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vehicle’s batteries. Batteries expel explosive gases. Failure to do so may result in
property damage, personal injury, and/or death.

WARNING!
Remove the ground cable from the negative terminal of the battery box before
disconnecting any electrical components. Always connect the ground cable last. Failure
to do so may result in property damage, personal injury, and/or death.
NOTE: Inspect vehicle for harness mounting bracket near spring hanger (Figure 1). If vehicle
is not equipped with harness mounting bracket at this location, obtain parts listed in Materials
Required and go to Step 7. If vehicle has harness mounting bracket then continue with
procedure.
REPAIR PROCEDURES

1. Inspect battery cables as they lead from the battery box to the starter for contact at the
spring hanger or bolt step.
2. If any cable is found to be damaged, such as insulation rubbed through and down to the
copper core, replace cables.
3. Inspect for cable mounting bracket (Figure 2). If bracket is installed, skip to step 7.

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IK0800382 - ProStar Battery Cable Routing - 12654

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4. Obtain parts listed in Materials Required.
5. Install harness mounting bracket (Figure 3) on left frame rail using 5/8 x 1 ½ in. bolt, 5/8 in.
lock washer and nut. Torque bolt to 120 lb.ft.
6. Install saddle and battery cables as described in steps 7c, 7d, and 7e.
7. Route cables as shown in Figure 3 following the steps below.
a. Cut the cable straps securing the cables to the saddle.
b. Remove the ¼ in. nut, and ¼ x 1 ¼ in. bolt securing the saddle to the harness mounting
bracket and remove saddle.
c. Install the saddle on the inside of the harness mounting bracket as shown in Figure 1
using the lower bolt hole.
d. Tighten nut to 105 lb-in (12 N·m).
e. Secure the cables to the saddle with new cable straps. When complete, negative cables
should be on the top side of the saddle, and the
positive cables should be at the bottom of the saddle (Figure 3). Repair is complete.

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IK0800382 - ProStar Battery Cable Routing - 12654

1. Positive Battery Cables
2. Saddle
3. Negative Battery Cables

Page 5 of 6

4. Harness Mounting Bracket
5. Spring Hanger
6. Cable Strap (2)

WARRANTY INFORMATION
Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the
normal manner as Warranty Code 40, Group 12654. It is important that the coding be
completed properly to assist in processing the warranty claim. Complete instructions will be
found in the Warranty Policy Manual, Section 7.1.8. As with all claim submission, items
acquired locally must be submitted in the .Other Charges. tab. The cost of any bulk items (bag
of cable tie straps, roll of wire, barrel of oil, tube of silicone, etc.) should be prorated for the
cost of the individual pieces/amount used during each repair.

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Warranty Claim Information
Group

Noun

Cause (C)

12654

Blank

2

Warranty
Description
Time (hrs)
Code
40
ProStar Battery Cable Routing As needed by SRT below

Standard Repair Time
Operation Number Description
Time (hrs)
Inspect Battery Cable
0.1
A08T1
Routing
A08T2
Re-route battery cables 0.2

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Copyright © 2012 Navistar, Inc.

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