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fix/528-v2
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docs/LAB-003-battery-disconnect-install.md
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docs/LAB-003-battery-disconnect-install.md
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# LAB-003: Truck Battery Disconnect Switch Installation
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**Issue:** [timmy-home#528](https://forge.alexanderwhitestone.com/Timmy_Foundation/timmy-home/issues/528)
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**Objective:** Eliminate parasitic battery drain via proper disconnect switch installation
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**Status:** Planning Complete — Ready for Execution
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---
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## Problem Statement
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Parasitic battery drain is killing the truck battery when parked. This is critical for operational mobility in a rural location where the truck is essential for:
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- Supply runs to Newport/Claremont
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- Emergency egress
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- Equipment transport
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The battery has likely been damaged from repeated deep discharges and may need replacement.
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---
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## Pre-Installation Checklist
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### Diagnostic Steps (Do These First)
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1. **Verify parasitic drain with multimeter:**
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- Set multimeter to DC Amps (10A scale)
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- Disconnect negative battery terminal
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- Connect multimeter in series between battery negative and cable
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- Normal drain: <50mA (0.05A)
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- Problem drain: >100mA (0.1A)
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- Record reading: __________ mA
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2. **Identify the culprit (if drain is high):**
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- While monitoring current, pull fuses one at a time
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- When current drops, you've found the circuit
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- Common culprits: aftermarket radio, alarm system, interior lights, OBD-II tracker
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3. **Test battery health:**
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- With engine off, battery voltage should be ~12.6V
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- With engine running, alternator should show ~13.7-14.7V
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- If voltage <12.4V when "fully charged," battery is degraded
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---
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## Shopping List
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### Required Items
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| Item | Purpose | Est. Cost | Stores |
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|------|---------|-----------|--------|
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| Battery disconnect switch (side-post or top-post) | Isolate battery when parked | $8-15 | AutoZone, Advance, O'Reilly, NAPA |
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| Terminal shim/post riser (if needed) | Ensure proper terminal clearance | $3-8 | Same as above |
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| Dielectric grease | Prevent corrosion on terminals | $3-5 | Same as above |
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| Battery terminal cleaner brush | Clean posts before install | $2-4 | Same as above |
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| **Total Estimated** | | **$15-30** | |
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### Product Recommendations
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#### Option 1: Top Terminal Post Mount (Most Common)
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- **Recommended:** Battery Doctor Knife Switch #20138 (Advance Auto)
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- $12-15
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- 250A continuous, 1000A surge
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- Easy quarter-turn operation
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- No tools needed to operate
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- **Alternative:** EverStart Battery Disconnect Switch (Walmart/AutoZone)
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- $8-12
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- 125A continuous
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- Twist-knob style
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#### Option 2: Side Terminal Mount (GM Vehicles)
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- **Recommended:** Battery Doctor Side Terminal Switch #20140
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- $12-18
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- Designed for GM-style side terminals
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- Requires terminal shim for proper fit
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#### Option 3: Quick-Disconnect (Side Post with Cable)
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- **Recommended:** Quick Cable Battery Disconnect #5091
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- $10-15
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- Works with existing cable ends
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- Marine-grade (good for NH weather)
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### Store Locations (Newport/Claremont Area)
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**AutoZone — Newport**
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- 65 Main St, Newport, NH 03773
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- (603) 863-5040
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- Hours: M-Sat 7:30AM-9PM, Sun 9AM-8PM
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**Advance Auto Parts — Newport**
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- 71 Main St, Newport, NH 03773
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- (603) 863-2860
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- Hours: M-Sat 7:30AM-9PM, Sun 9AM-7PM
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**O'Reilly Auto Parts — Claremont**
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- 385 Washington St, Claremont, NH 03743
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- (603) 542-4635
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- Hours: M-Sat 7:30AM-9PM, Sun 9AM-8PM
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**NAPA Auto Parts — Newport**
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- 29 John Stark Hwy, Newport, NH 03773
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- (603) 863-5500
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- Hours: M-F 7:30AM-6PM, Sat 7:30AM-4PM, Sun Closed
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---
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## Installation Procedure
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### Tools Required
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- 10mm wrench (for most battery terminals)
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- 13mm wrench (if GM side terminals)
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- Wire brush or terminal cleaner
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- Shop rags
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- Optional: zip ties for cable management
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### Step-by-Step Installation
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1. **Safety First**
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- Park on level ground
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- Engage parking brake
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- Remove keys from ignition
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- Wear safety glasses
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2. **Disconnect Battery**
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- **CRITICAL:** Disconnect NEGATIVE (-) terminal FIRST
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- This prevents short circuits if wrench touches frame
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- Loosen 10mm nut, wiggle terminal off post
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- Tuck cable away so it can't touch battery post
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3. **Clean Terminals**
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- Use terminal brush to clean inside of cable clamp
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- Clean battery post until shiny
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- Apply thin layer of dielectric grease to post
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4. **Install Disconnect Switch**
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**For Top Post Batteries:**
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- Remove battery cable end from switch (if pre-attached)
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- Slide switch onto battery negative post
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- Re-attach cable to other side of switch
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- Tighten securely (don't overtighten — battery posts strip easily)
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**For Side Terminal (GM) Batteries:**
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- May need terminal shim/post riser for clearance
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- Install shim on negative side terminal
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- Mount switch to shim
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- Connect cable to switch
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**For Cable-End Style:**
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- Cut existing negative cable near battery (leave enough slack)
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- Strip 1/2" of insulation from both ends
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- Install in quick-disconnect connector
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- Crimp or bolt securely per manufacturer instructions
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5. **Test Installation**
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- Switch should rotate/turn smoothly
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- No binding or interference with battery hold-down
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- Cable has enough slack for switch operation
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- Switch in "ON" position: truck electronics work
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- Switch in "OFF" position: no power to truck
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6. **Reconnect and Verify**
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- Switch to ON position
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- Attempt to start truck — should start normally
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- Check all electronics function
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- Switch to OFF position
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- Verify no interior lights, radio, etc.
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---
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## Testing Protocol
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### Immediate Test (Same Day)
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- [ ] Start truck with switch ON — engine starts normally
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- [ ] Turn switch OFF while running — engine dies (expected)
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- [ ] Switch OFF, wait 30 seconds, attempt start — no response (expected)
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- [ ] Switch ON, attempt start — starts normally
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### Overnight Test (Critical)
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- [ ] Park truck with switch in OFF position
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- [ ] Note battery voltage: __________ V
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- [ ] Wait 24 hours
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- [ ] Next day, switch ON, attempt start
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- [ ] Record result: □ Started normally □ Slow crank □ No start
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- [ ] If started, check voltage: __________ V
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### 48-Hour Test (If Battery Healthy)
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- [ ] Repeat overnight test with 48-hour duration
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- [ ] If truck starts normally, installation is successful
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- [ ] If truck fails to start, battery replacement needed
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---
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## If Battery Needs Replacement
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### Symptoms of Bad Battery
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- Voltage <12.4V after "charging" overnight
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- Slow cranking even with switch disconnected
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- Battery case bulging or terminals corroded
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- Battery >4 years old
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### Replacement Battery Shopping
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**Common Truck Batteries (Group Size):**
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- Measure existing battery or check current battery label
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- Common truck sizes: Group 24F, 27F, 31, 65, 78
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**Recommended:**
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- **DieHard Platinum AGM** (Advance Auto) — $200-250
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- Best cold cranking amps (CCA) for NH winters
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- AGM handles deep discharges better
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- 3-year full replacement warranty
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- **EverStart Maxx** (Walmart) — $100-150
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- Budget option
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- Check CCA rating matches or exceeds old battery
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- **Optima YellowTop** (Pep Boys/Amazon) — $300+
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- Deep cycle + starting
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- Best for vehicles with parasitic drain issues
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- Handles repeated discharge cycles
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---
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## Documentation Requirements
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Per issue #528 acceptance criteria, upload to Gitea:
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- [ ] Photo of installed disconnect switch (close-up)
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- [ ] Photo of receipt from parts store
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- [ ] Photo of truck odometer (optional, for record)
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- [ ] Note of test results (overnight start success/failure)
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- [ ] Note of battery voltage readings (before/after)
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Upload via:
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1. Open issue #528 in browser
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2. Comment with photos attached
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3. Check off acceptance criteria
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---
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## Troubleshooting
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| Problem | Cause | Solution |
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|---------|-------|----------|
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| Switch won't tighten on post | Wrong terminal type | Get side-terminal adapter or different switch style |
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| Switch hits battery hold-down | Clearance issue | Add terminal shim to raise switch, or relocate hold-down |
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| Cable too short | Switch adds height | Get battery cable extension or longer replacement cable |
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| Still drains with switch OFF | Switch installed on wrong terminal | Move to NEGATIVE terminal only |
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| Switch gets hot | Loose connection | Tighten terminal nuts; check for corrosion |
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| Truck won't start even with switch ON | Battery too dead | Jump start, then evaluate if battery needs replacement |
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---
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## Cold Weather Considerations (NH)
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- Batteries lose ~50% capacity at 0°F
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- Disconnect switch prevents drain but doesn't prevent cold damage
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- If storing truck long-term:
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- Switch to OFF
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- Consider battery maintainer (trickle charger)
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- Or remove battery and store in heated space
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---
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## Summary
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This installation is straightforward and should take 30-60 minutes including store run. The key steps:
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1. **Diagnose first** — verify parasitic drain, check battery health
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2. **Buy the right switch** — match your battery terminal type (top vs side)
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3. **Install on NEGATIVE terminal only** — this is critical for safety
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4. **Test thoroughly** — overnight test proves the fix worked
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5. **Document** — photos and receipts to close the issue
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**Estimated total time:** 2-3 hours (including store run)
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**Estimated cost:** $15-30 (switch only) or $100-300 (if battery replacement needed)
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---
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*Prepared for: timmy-home#528*
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*Last updated: 2026-04-22*
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109
docs/LAB-003-verification-template.md
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109
docs/LAB-003-verification-template.md
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# LAB-003 Verification Report Template
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**Issue:** [timmy-home#528](https://forge.alexanderwhitestone.com/Timmy_Foundation/timmy-home/issues/528)
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**Date:** __________
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**Technician:** __________
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---
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## Pre-Installation Diagnostics
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| Test | Reading | Normal Range | Status |
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|------|---------|--------------|--------|
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| Battery Voltage (engine off) | _____ V | 12.4-12.7V | □ Pass □ Fail |
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| Parasitic Current | _____ mA | <50mA | □ Pass □ Fail |
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| Battery Voltage (engine running) | _____ V | 13.7-14.7V | □ Pass □ Fail |
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**Battery Health Assessment:** □ Good □ Fair □ Replace
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---
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## Parts Purchased
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| Item | Store | Cost |
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|------|-------|------|
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| Battery Disconnect Switch | _________ | $_____ |
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| Dielectric Grease | _________ | $_____ |
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| Terminal Cleaner | _________ | $_____ |
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| Other: _________ | _________ | $_____ |
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| **Total** | | **$_____** |
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---
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## Installation Checklist
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- [ ] Negative terminal disconnected first
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- [ ] Terminals cleaned
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- [ ] Dielectric grease applied
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- [ ] Switch installed on NEGATIVE terminal
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- [ ] All connections tight
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- [ ] Switch operates smoothly (no tools needed)
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- [ ] No interference with hood/battery hold-down
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---
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## Post-Installation Tests
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### Immediate Tests
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- [ ] Truck starts with switch ON
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- [ ] No power with switch OFF
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- [ ] All electronics function normally (switch ON)
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### 24-Hour Test
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- [ ] Parked with switch OFF for 24+ hours
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- [ ] Truck started normally next day
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- [ ] Battery voltage before test: _____ V
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- [ ] Battery voltage after test: _____ V
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### 48-Hour Test (if applicable)
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- [ ] Parked with switch OFF for 48+ hours
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- [ ] Truck started normally
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---
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## Photos Required
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Upload these to issue #528:
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- [ ] Photo of installed disconnect switch (close-up)
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- [ ] Photo of receipt from parts store
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- [ ] Photo showing switch in OFF position
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- [ ] Photo of truck dashboard (optional, for records)
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---
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## Results Summary
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| Acceptance Criterion | Status |
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|---------------------|--------|
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| Disconnect switch installed and physically secure | □ Pass □ Fail |
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| Truck starts reliably after 24+ hours with switch disconnected | □ Pass □ Fail |
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| No special tools required to operate the disconnect | □ Pass □ Fail |
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| Receipt uploaded to issue | □ Pass □ Fail |
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**Overall Status:** □ Complete - All criteria met
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□ Partial - See notes
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□ Failed - Requires follow-up
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||||
---
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## Notes / Issues Encountered
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_________________________________________________________________
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||||
_________________________________________________________________
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||||
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||||
_________________________________________________________________
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||||
|
||||
---
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## Follow-up Actions (if needed)
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- [ ] Replace battery (if tests failed)
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- [ ] Exchange switch for different style (if fitment issue)
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- [ ] Troubleshoot remaining parasitic drain
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- [ ] Other: _____________________________________________
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---
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*Fill out this template during installation and upload to issue #528*
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215
scripts/lab_003_battery_disconnect.sh
Executable file
215
scripts/lab_003_battery_disconnect.sh
Executable file
@@ -0,0 +1,215 @@
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#!/bin/bash
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||||
#
|
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# LAB-003 Battery Disconnect Installation Helper
|
||||
# Reference: timmy-home#528
|
||||
#
|
||||
# Usage:
|
||||
# bash scripts/lab_003_battery_disconnect.sh diagnose # Test battery before install
|
||||
# bash scripts/lab_003_battery_disconnect.sh checklist # Print installation checklist
|
||||
# bash scripts/lab_003_battery_disconnect.sh verify # Post-install verification
|
||||
#
|
||||
|
||||
set -euo pipefail
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|
||||
SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
|
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LOG_FILE="$SCRIPT_DIR/../logs/lab_003_$(date +%Y%m%d_%H%M%S).log"
|
||||
ISSUE_URL="https://forge.alexanderwhitestone.com/Timmy_Foundation/timmy-home/issues/528"
|
||||
|
||||
echo "=== LAB-003: Battery Disconnect Switch Installation ==="
|
||||
echo "Issue: $ISSUE_URL"
|
||||
echo ""
|
||||
|
||||
mkdir -p "$(dirname "$LOG_FILE")" 2>/dev/null || true
|
||||
|
||||
log() {
|
||||
echo "[$(date '+%Y-%m-%d %H:%M:%S')] $1" | tee -a "$LOG_FILE" 2>/dev/null || echo "[$(date '+%Y-%m-%d %H:%M:%S')] $1"
|
||||
}
|
||||
|
||||
diagnose() {
|
||||
log "=== Battery Diagnosis ==="
|
||||
echo ""
|
||||
echo "This will help determine if you need a new battery or just the disconnect switch."
|
||||
echo ""
|
||||
|
||||
echo "Step 1: Check battery voltage with multimeter"
|
||||
echo " - Set multimeter to DC Volts (20V scale)"
|
||||
echo " - Red probe to battery positive (+)"
|
||||
echo " - Black probe to battery negative (-)"
|
||||
echo ""
|
||||
read -p "Enter voltage reading (e.g., 12.6): " voltage
|
||||
log "Battery voltage: ${voltage}V"
|
||||
|
||||
if (( $(echo "$voltage >= 12.6" | bc -l) )); then
|
||||
echo "✓ Battery voltage is GOOD (≥12.6V)"
|
||||
log "Battery voltage GOOD"
|
||||
elif (( $(echo "$voltage >= 12.4" | bc -l) )); then
|
||||
echo "⚠ Battery voltage is FAIR (12.4-12.5V) - may need replacement soon"
|
||||
log "Battery voltage FAIR"
|
||||
else
|
||||
echo "✗ Battery voltage is LOW (<12.4V) - likely needs replacement"
|
||||
log "Battery voltage LOW - replacement recommended"
|
||||
fi
|
||||
|
||||
echo ""
|
||||
echo "Step 2: Check for parasitic drain"
|
||||
echo " - Set multimeter to DC Amps (10A scale)"
|
||||
echo " - Disconnect negative battery cable"
|
||||
echo " - Connect multimeter between battery negative post and cable"
|
||||
echo " - Wait 2 minutes for modules to sleep"
|
||||
echo ""
|
||||
read -p "Enter current reading in milliamps (e.g., 50): " current
|
||||
log "Parasitic current: ${current}mA"
|
||||
|
||||
if (( $(echo "$current <= 50" | bc -l) )); then
|
||||
echo "✓ Parasitic drain is NORMAL (≤50mA)"
|
||||
log "Parasitic drain NORMAL"
|
||||
echo ""
|
||||
echo "NOTE: Normal drain means the disconnect switch may not be necessary"
|
||||
echo " unless you're storing the truck for weeks at a time."
|
||||
elif (( $(echo "$current <= 100" | bc -l) )); then
|
||||
echo "⚠ Parasitic drain is ELEVATED (50-100mA)"
|
||||
log "Parasitic drain ELEVATED"
|
||||
echo "Disconnect switch will help prevent dead battery."
|
||||
else
|
||||
echo "✗ Parasitic drain is HIGH (>100mA)"
|
||||
log "Parasitic drain HIGH - disconnect switch highly recommended"
|
||||
echo ""
|
||||
echo "You definitely need the disconnect switch!"
|
||||
fi
|
||||
|
||||
echo ""
|
||||
log "Diagnosis complete. Log saved to: $LOG_FILE"
|
||||
}
|
||||
|
||||
checklist() {
|
||||
cat << 'EOF'
|
||||
=== LAB-003 Installation Checklist ===
|
||||
|
||||
BEFORE YOU GO:
|
||||
□ Determine battery terminal type (top post vs side terminal)
|
||||
□ Measure battery group size (look for label like "Group 24F")
|
||||
□ Check if you have 10mm and 13mm wrenches
|
||||
□ Verify multimeter has DC Volts and DC Amps capability
|
||||
|
||||
AT THE STORE:
|
||||
□ Purchase battery disconnect switch (match your terminal type)
|
||||
□ Purchase dielectric grease
|
||||
□ Purchase terminal cleaner brush (if you don't have one)
|
||||
□ Get receipt for documentation
|
||||
|
||||
INSTALLATION:
|
||||
□ Park on level ground, engage parking brake
|
||||
□ Disconnect NEGATIVE (-) terminal first
|
||||
□ Clean terminals with wire brush
|
||||
□ Apply dielectric grease
|
||||
□ Install switch on NEGATIVE terminal
|
||||
□ Reconnect and test operation
|
||||
|
||||
TESTING:
|
||||
□ Switch ON: truck starts normally
|
||||
□ Switch OFF: no power to truck
|
||||
□ Overnight test: switch OFF, verify start next day
|
||||
□ Document with photos
|
||||
□ Upload photos to issue #528
|
||||
|
||||
TROUBLESHOOTING:
|
||||
□ If switch doesn't fit: wrong terminal type - exchange at store
|
||||
□ If still drains overnight: battery needs replacement
|
||||
□ If slow crank with new switch: battery degraded - replace
|
||||
|
||||
EOF
|
||||
}
|
||||
|
||||
verify() {
|
||||
log "=== Post-Installation Verification ==="
|
||||
echo ""
|
||||
echo "Post-installation tests. Run these AFTER installing the disconnect switch."
|
||||
echo ""
|
||||
|
||||
read -p "Test 1 - Can you start the truck with the switch ON? (y/n): " t1
|
||||
if [[ "$t1" == "y" ]]; then
|
||||
log "Test 1 PASSED: Truck starts with switch ON"
|
||||
echo "✓ Test 1 PASSED"
|
||||
else
|
||||
log "Test 1 FAILED: Truck won't start with switch ON"
|
||||
echo "✗ Test 1 FAILED - Check installation and battery"
|
||||
fi
|
||||
|
||||
echo ""
|
||||
read -p "Test 2 - With truck OFF and switch OFF, do interior lights/radio work? (y/n): " t2
|
||||
if [[ "$t2" == "n" ]]; then
|
||||
log "Test 2 PASSED: No power with switch OFF"
|
||||
echo "✓ Test 2 PASSED"
|
||||
else
|
||||
log "Test 2 FAILED: Power still on with switch OFF"
|
||||
echo "✗ Test 2 FAILED - Switch may be on wrong terminal or defective"
|
||||
fi
|
||||
|
||||
echo ""
|
||||
read -p "Test 3 - Is the switch easy to operate by hand (no tools needed)? (y/n): " t3
|
||||
if [[ "$t3" == "y" ]]; then
|
||||
log "Test 3 PASSED: Switch operable without tools"
|
||||
echo "✓ Test 3 PASSED"
|
||||
else
|
||||
log "Test 3 WARNING: Switch may require tools"
|
||||
echo "⚠ Test 3 WARNING - Consider a different switch style"
|
||||
fi
|
||||
|
||||
echo ""
|
||||
echo "=== 24-Hour Test ==="
|
||||
echo "Park truck with switch OFF. Tomorrow, try to start it."
|
||||
echo "Record result in issue #528: $ISSUE_URL"
|
||||
echo ""
|
||||
|
||||
read -p "Did the 24-hour test pass (truck started normally)? (y/n/skip): " t24
|
||||
case "$t24" in
|
||||
y)
|
||||
log "24-hour test PASSED"
|
||||
echo "✓ Installation SUCCESSFUL!"
|
||||
echo ""
|
||||
echo "Close issue #528 with:"
|
||||
echo " - Photo of installed switch"
|
||||
echo " - Photo of receipt"
|
||||
echo " - Note: '24-hour test passed, truck started normally'"
|
||||
;;
|
||||
n)
|
||||
log "24-hour test FAILED"
|
||||
echo "✗ Test FAILED - Battery likely needs replacement"
|
||||
echo ""
|
||||
echo "Next steps:"
|
||||
echo " 1. Jump start truck"
|
||||
echo " 2. Drive to store for battery replacement"
|
||||
echo " 3. Reference LAB-003-battery-disconnect-install.md for battery shopping guide"
|
||||
;;
|
||||
*)
|
||||
log "24-hour test pending"
|
||||
echo "Run this script again after 24 hours with: bash $0 verify"
|
||||
;;
|
||||
esac
|
||||
|
||||
echo ""
|
||||
log "Verification complete. Log saved to: $LOG_FILE"
|
||||
}
|
||||
|
||||
case "${1:-help}" in
|
||||
diagnose)
|
||||
diagnose
|
||||
;;
|
||||
checklist)
|
||||
checklist
|
||||
;;
|
||||
verify)
|
||||
verify
|
||||
;;
|
||||
*)
|
||||
echo "Usage: $0 {diagnose|checklist|verify}"
|
||||
echo ""
|
||||
echo " diagnose - Check battery voltage and parasitic drain"
|
||||
echo " checklist - Print installation checklist"
|
||||
echo " verify - Post-installation verification tests"
|
||||
echo ""
|
||||
echo "Full guide: docs/LAB-003-battery-disconnect-install.md"
|
||||
echo "Issue: $ISSUE_URL"
|
||||
exit 1
|
||||
;;
|
||||
esac
|
||||
Reference in New Issue
Block a user