Section 4 - ADJUSTMENTS & REPAIR
Battery Condition Chart
| State of Charge | Syringe Hydrometer | Digital Voltmeter | Five Ball Hydrometer |
100% | Charged w/ Sulfate Stop | 1.280 | 12.80v | Five Balls Floating |
100% | Charged | 1.265 | 12.60v | Four Balls Floating |
75% Charged | 1.210 | 12.40v | Three Balls Floating | |
50% Charged | 1.160 | 12.10v | Two Balls Floating | |
25% Charged | 1.120 | 11.90v | One Ball Floating | |
0% Charged | Less than 1.100 | Less than 11.80v | Zero Balls Floating | |
4.7.4.BATTERY TESTING
There are two types of battery tests: Unloaded and Loaded. The unloaded test is the procedure that will be discussed. It’s the simplest and most commonly used. An unloaded test is made on a battery without discharging current. To perform unloaded testing, check charge condition using either a hydrometer or voltmeter.
1.Using a voltmeter, voltage readings appear instantly to show the state of charge. Remember to hook the positive lead to the battery’s positive terminal, and the negative lead to the negative terminal.
2.A hydrometer measures the specific gravity of each cell. The specific gravity tells the degree of charge; generally, a specific gravity of about 1.265 to 1.280 indicates full charge. A reading of 1.230 to 1.260 indicates the battery should be charged before testing. The chart on the next page shows the charge level as measured by syringe float hydrometer, digital voltmeter and five ball hydrometer.
4.7.5.NEW BATTERY PREPARATION 1. Remove battery from carton.
2. Place battery in a well ventilated area on a level
3. Remove battery cell caps. Fill cells as required with electrolyte (purchased separately) to proper level. Fill to 3/16” above cell plates. Filling battery with electrolyte will bring the battery to 80% charged state.
4. With cell caps removed, connect battery charger to battery terminals; RED to positive (+) and BLACK to negative
IMPORTANT: 3/16” above cell plates is the recommended level. DO NOT place anything in battery other than specified electrolyte.
WARNING
DO NOT OVERFILL!
WARNING
DO NOT attempt to service or charge the battery while it is installed in the machine. DO NOT use “BOOST” chargers on the battery.
5.Slow charge the battery at 1 amp for 2 hours to bring the battery to full charge.
6.After charging, check level of electrolyte and add as needed to bring level to 3/16” above cell plates.
7.Reinstall cell caps.
8.Install battery into power unit.
9.Connect positive (+) cable (red) first, from wiring harness to the positive terminal (+) on battery using bolt and nut provided in hardware bag. Connect negative
10.Install battery retainer and positive terminal cover.
WARNING
Shield the positive terminal with terminal cover located on battery harness. This prevents metal from touching the positive terminal which could cause sparks. Cables must be connected to battery terminals in the proper position. RED (Positive) cable must go to the ( + ) terminal. BLACK (Negative) cable must go to the ( - ) terminal.
20