Trouble-Shooting; Preparation For Testing; On-Charge Voltage Testing - Hammerhead Charger 48V Operator's Manual

TROJAN BATTERY USER'S GUIDE
7.

Trouble-Shooting

These battery testing procedures are guidelines only for identifying a battery that may
need to be replaced. Unique situations may be observed that are not identified within
this procedure. Please contact Trojan Battery Company's technical support engineers at
800-423-6569 or +1-562-236-3000 for help interpreting the test data.

Preparation for Testing

7.1.
• Check that all vent caps are secured properly on the battery
• Clean the top of the battery, terminals and connections with a cloth or brush and a
solution of baking soda and water. Do not allow cleaning solution to get inside the
battery. Rinse with water and dry with a clean cloth
• Check battery cables and connections. Replace any damaged cables. Tighten any
loose connections. Refer to Torque Values
• For flooded/wet batteries, check the electrolyte level and add water if necessary.
Refer to Watering
• Fully charge batteries

On-Charge Voltage Testing

7.2.
• Disconnect and reconnect DC plug to restart charger
• While the batteries are on-charge record the current in the last ½ hour of charge (if
possible) and measure the battery set voltage
• If the current at the end of charge is below 5 amps and the battery set voltage is
above: 56V for a 48V system; 42V for a 36V system; 28V for a 24V system; 14V for
a 12V battery; 9.3V for a 8V battery or 7V for a 6V battery, then proceed to the next
step. Otherwise check the charger for proper output and recharge the batteries if
necessary. If the set voltages are still low, you may have a failed battery
• While the batteries are on-charge measure the individual battery voltages
• If any battery voltage is below: 7V for 6V battery, 9.3V for 8V battery and 14V for 12V
battery, and a voltage variation is greater than 0.5V for 6V battery or 1.0V for a 12V
battery, from any other battery in set, it may be a failed battery
17
section 3.3
section 2.2.2