Dealer Development Center, Pune
60
Pulsar DTS-i 150/180 Training Notes
happens, the chemical reactions within the battery
are affected and results in loss of capacity. Mostly
the causes of sulphation are as under :
a. Undercharging.
b. Standing in a partially or completely discharge
condition for long time.
c. Low electrolyte level : If electrolyte level is
permitted to fall below the top of the battery
plates, then the exposed surfaces will harden
and will become sulphated.
d. Adding acid : If acid is added to a cell in which
sulphation exists the condition will be
aggravated.
e. High specific gravity : If specific gravity is higher
than the recommended value, then sulphation
may occur.
f. High temp.: High temperature accelerates
sulphation, particularly of an idle, partially
discharged battery.
Voltage of the sulphated battery : -
Cells of the sulphated battery will show low specific
gravity. Follow the procedure given below.
• Check voltage before charging.
• Charge for 2 hours
• Check voltage every 1 hour. If voltage increases
then continue charging. But if voltage does not
increase, discontinue charging. Otherwise battery
charger will get permanently damaged. If battery
is not badly sulphated (i.e. voltage more than 9
volts), then battery can be revived by special
treatment. In such case it is advisable to give
sulphated battery to authorised dealer of battery
manufacturer for necessary special treatment.
Battery Maintenance
For the optimum performance and longer battery
life the maintenance of battery is important.
a. Always keep the battery clean and dry.
b. Visually inspect the surface of the battery
container. If there are any signs of cracking or
electrolyte leakage from battery, replace the
battery.
Never add acid or ordinary tap water for topping
up since this will shorten Battery life.
Non Use Maintenance
When the vehicle is likely to remain off-road for
longer, time (say more than a month) then Non
Use Maintenance should be carried out as follows
otherwise the battery may get sulphated and
permanently damaged.
a. Remove the battery from vehicle.
b. Maintain electrolyte at ‘Upper Level’.
c. During off service period, battery should be
charged once a month or if the battery DC
voltage drops below 12.3 V.
d. Keep the battery fully charged.
e. Store the battery in cool, dry place.
f. Keep the battery away from rain, dew,
moisture and direct sunlight.
How to Determine Condition of Battery
Specific gravity check: - Whether battery is fully
charged or partially charged, it will always show
same “no load voltage” of 12 volts or more
(unless battery cells are damaged due to
sulphation etc). But specific gravity of the fully
charged battery and partially charged battery will
be different. Fully charged battery will show Sp.
gravity of 1.240 while partially charged battery will
show less specific gravity. Therefore, specific
gravity check is very important to know condition
of the battery.
•
Top up level with distilled water to max level
when the electrolyte level is less than half of
min & max level.
•
Connect battery to charge & ensure respective
terminal are connected properly.
•
Set charging current at 0.9 A DC.
•
Charge battery for 3/4 hrs., then check voltage
and special gravity.
•
Battery open circuit voltage should be > 12.5
volts (when disconnected from charger) &
special gravity in all 6 cells should be 1.240.
This is a confirmation check for a fully charged
battery.
•
Disconnect the battery from the charger.
•
Fit gang bar plug firmly.
•
Using the battery load tester confirm for good
indication of state of charge of battery.
•
Connect battery on to vehicle.
•
Apply petroleum jelly on battery terminal.
Battery Sulphation
A sulphated battery is one which has been left
standing in a discharged condition or undercharged
to the point where abnormal lead sulphate has
formed on the plates (Sulphate cells looks like
white crystal like sugar). Where this
Maintenance - Electrical
Note :
Use of battery load tester will give the correct
indication of state of charge of battery on load
conditions.
Dealer Development Center, Pune
61
Pulsar DTS-i 150/180 Training Notes
Maintenance - Electrical
Switches :
Front Brake Light Switch Inspection :
•
Turn ON the ignition switch.
•
The brake Light LED Blank should get on when the
front brake (Lever is pressed) is applied.
•
If it does not, check the Front brake switch.
Lever Pressed
Lever Released
Brown
Blue
Rear Brake Light Switch Timing Inspection :
•
Turn ON the ignition switch.
•
Check the operation of the rear brake light switch by
depressing the brake pedal
•
If it does not operate as specified, adjust the brake light
switch or check the switch.
Pedal Pressed
Pedal Released
Brown
Blue
Ignition Switch :
‘OFF’
‘OFF’
Brown/Blue
White
Neutral Switch :
•
The neutral switch will be in ON position only when the
engine is in neutral.
•
The neutral light will not glow when vehicle is in gear.
‘ON’ (Vehicle in neutral)
‘OFF’ (Vehicle in gear)
Light Green Bve
