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Section 5 - ADJUSTMENTS
& REPAIR
Battery
Condition
Chart
State of Charge
100% Charged w/Sulfate
Stop
100% Charged
75% Charged
50% Charged
25% Charged
0% Charged
Syringe
Hydrometer
1.280
1.265
1.210
1.160
1.120
Less than 1.100
Digital Voltmeter
12.80v
12.60v
12.40v
12.10v
11.90v
Lessthan
11.80v
Five Ball Hydrometer
Five Balls Floating
Four Balls Floating
Three Balls Floating
Two Balls Floating
One Ball Floating
Zero Balls Floating
5.9.4, 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 fulI charge. A reading of 1.230
to 1.260 indicates the battery should be charged
before testing. The Battery Condition Chart shows
the charge
level as measured
by syringe float
hydrometer,
digital
voltmeter
and
five-ball
hydrometer.
5.9.5, NEW BATTERY PREPARATION
1. Remove battery from carton.
2, Place battery in a well ventilated area on a Ievel
non-concrete surface.
3. Remove battery cell caps. Fill cells as required
with electrolyte
(purchased
separately)
to proper
level. Filling battery with electrolyte will bring the
battery to 80% charged state.
4, With
cell
caps
removed,
connect
battery
charger to battery terminaIs;
RED to positive (+)
and BLACK to negative (-) terminal.
WARNING
AI
DO NOT attempt to service or charge
the battery I
while
it is installed
in the machine.
DO NOT use I
"BOOST"
chargers on the battery.
I
5. Slow charge the battery at 1 amp for 10 hours
to bring the battery to fulI charge.
6. After charging, check level of electrolyte
and
add as needed to bring to proper level
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 (-) cable (black) last, to
negative terminal (-) on battery using bolt and nut.
Apply a small amount of grease over terminals to
prevent corrosion.
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.
IMPORTANT:
DO NOT place anything in battery other
than specified electrolyte.
i WARNING
DO NOT OVERFILL!
26
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