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Owner’s Guide
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
permanent damage to the battery. To prevent damage, the battery must be charged again. Use a hydrometer to find the
specific gravity and the state of charge of a battery (Figure 9).
In winter conditions, the battery must be completely charged to prevent the risk of freezing. A completely charged battery
will not freeze in temperatures above -75° F (-60° C). Although the chemical reaction is decreased in cold temperatures,
the battery must be stored completely charged, and disconnected from circuits that can discharge the battery. The con-
troller must be disconnected from the batteries by disconnecting the battery cables.
For portable chargers, disconnect the charger plug from the vehicle receptacle.
For on-board chargers, disconnect the charging harness from the batteries.
The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge.
The batteries must be tested or charged again at 0 day minimum intervals.
Battery Charging
The battery charger is designed to completely charge the battery set. If the batteries are severely deep cycled, some
automatic battery chargers contain an electronic module that will not activate and the battery charger will not operate.
Automatic chargers determine the correct length of charge to the battery set and turns off when the batteries are
charged. Always refer to the instructions of the charger used.
Do not overfill batteries. The charge cycle will expel electrolyte and cause component damage.
Before charging, the following must be observed:
•
The electrolyte level in all cells must be at the recommended level and above the plates.
•
The charging must occur in an area with good ventilation to remove hydrogen gas that is made during the
charge cycle. A minimum
of five air replacements for each hour is recommended.
•
The charger connector components must be in good condition and free from dirt and particles.
•
The charger connector must be completely installed in the vehicle receptacle.
•
The charger connector and cord set must be protected from damage. The charger connector and cord set must
be used in an area where it is not possible for personnel to run over or trip over the cord set.
•
The charger automatically turns off during the connect and disconnect cycle so no electrical arc is generated at
the DC plug and receptacle contacts.
AC Voltage
The battery charger output is directly related to the input voltage. If the vehicle receives an incomplete charge in a nor-
mally adequate time period, low AC voltage can be the cause. Consult an electrician if necessary.
Fault Diagnosis
Fault diagnosis is done for two reasons:
•
A battery that performs poorly and is outside of the manufacturers specification must be identified to replace it within
the terms of the manufacturer’s warranty. Different manufacturers have different requirements. Refer the battery
manufacturer or the manufacturer’s representative for specified requirements.
•
Find the reason a vehicle does not perform adequately. Performance problems can cause a vehicle to run slowly or
can not operate for the time needed.
A new battery must mature before it develops its maximum capacity. Maturing can take 100 or more charge and dis-
charge cycles. After the maturing phase, the older a battery gets, the lower the capacity. The only method to find the
capacity of a battery is a load test with a discharge machine. Refer to the discharge machine manufacturer instructions.
A hydrometer is used to identify a poorly performing battery in a set with a low specific gravity. When the particular cell or
cells that are the problem are identified, the battery can be removed and replaced. The battery can not be restored. The
individual battery should be replaced with a good battery of the same brand, type and approximate age.
