Page H-2
Repair and Service Manual
B
BATTERIES AND CHARGING
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
At Each Charging Cycle
To reduce the possibility of fire, never attach a
battery charger to a vehicle that is to be unat-
tended beyond the normal charging cycle.
Overcharging could cause damage to the vehi-
cle batteries and result in extreme overheating.
The charger should be checked after 24 hours
and unplugged after the charge cycle is com-
plete.
Before charging the batteries, inspect the plug of the
battery charger and vehicle receptacle housing for dirt or
debris.
Charge the batteries after each days use.
Monthly
•
Inspect all wiring for fraying, loose terminations,
corrosion or deterioration of insulation.
•
Check that the electrolyte level is correct and add
suitable water as required.
•
Clean the batteries and wire terminations.
Electrolyte Level and Water
The correct level of the electrolyte is 1/2" (13 mm) above
the plates in each cell (Ref. Fig. 1 on Page H-2).
Fig. 1 Correct Electrolyte Level
This level will leave approximately 1/4" - 3/8" (6 - 10
mm) of space between the electrolyte and the vent tube.
The electrolyte level is important since any portion of
the plates exposed to air will be ruined beyond repair. Of
equal importance is too much water which will result in
electrolyte being forced out of the battery due to gassing
and the increase in volume of the electrolyte that results
from the charging cycle.
Do not overfill batteries. The charging cycle will expel
electrolyte and result in component damage.
A battery being charged will ‘gas’ with the majority of the
gassing taking place at the end of the charging cycle.
This gas is hydrogen which is lighter than air. Water and
sulfuric acid droplets will be carried out of the battery
vents by the hydrogen gas; however, this loss is mini-
mal. If the battery electrolyte level is too high, the elec-
trolyte will block the vent tube and the gas will force it
out of the vent tube and battery cap. The water will
evaporate but the sulfuric acid will remain where it can
damage vehicle components and the storage facility
floor. Sulfuric acid loss will weaken the concentration of
acid within the electrolyte and reduce the life of the bat-
tery.
Over the life of the battery, a considerable amount of
water is consumed. It is important that the water used be
pure and free of contaminants that could reduce the life
of the battery by reducing the chemical reaction. The
water must be distilled or purified by an efficient filtration
system. Water that is not distilled should be analyzed
and if required, filtration installed to permit the water to
meet the requirements of the water purity table (Ref. Fig.
2 on Page H-2).
Fig. 2 Water Purity Table
Even if the water is colorless, odorless, tasteless and fit
for drinking, the water should be analyzed to see that it
does not exceed the impurity levels specified in the
table.
Automatic watering devices such as the one included in
the Battery Maintenance Kit (P/N 25587-G01) can be
used with an approved water source (Ref. Fig. 3 on
Page H-3). These watering devices are fast and accu-
rate to use and maintain the correct electrolyte level
within the battery cells.
Vent Cap
Gas Vent
Vent
Expansion
Space
Plates
1/2” (13 mm)
1/4” to 3/8”
(6 mm to 10mm)
Electrolyte level should be at least
1/2” (13mm) above the plates and 1/4”
to 3/8” (6 to 10 mm) below vent
