BATTERY TEST PROCEDURE Introduction To determine the ability of a battery to function properly requires testing. The accuracy of the testing changes with temperature, specific gravity, age of the battery, etc. An accurate test has more than one step. Step 1 : Visual Inspection Step 2 : Specific gravity check (Hydrometer) Step 3: Load Test Testing Waring: Wear safety glasses. Do not break live circuits at battery terminals. When testing, be certain to remove gases at battery cover caused by charging. STEP 1 FOR_OBVIOUS DAMAGE SUCH AS OR BROKEN CASE THAT SHOWS LOSS OF ELECTROLYTE [OBVIOUS DAMAGE NO_OBVIOUS DAMAGE. [REPLACE BATTERY ] [CHECK ELECTROLYTE LEVEL LOW TOP OF PLATES IN ONE Of MORE CELLS] ELECTROLYTE LEVEL ABOVE TOP OF PLATES| IN ALL CELLS PROCEED TO STEP 2 }ADD WATER TO JUST ABOVE SEPARATORS BUT ‘NOT TO SPLIT RING. CHARGE FOR 15 MIN. @ 15-25 AMPS WITH WON-FLANE. [ARRESTER VENT CAPS REMOVED. BBUT LEAVE FLAME ARRESTER CAPS IN PLACE. = PROCEED TO STEP 2. LESS THAN 50. POINTS VARIATION BETWEEN HIGHEST AND LOWEST CELL '50 POINTS OR MORE VARIATION BETWEEN HIGHEST AND LOWEST CELLSTEP 3 CHARGE BATTERY, IF NECESSARY, UNTIL ALL CELLS ARE AT LEAST 1.200 SPECIFIC GRAVITY REMOVE ALL VENT CAPS TF UNABLE TO OBTAIN SPECIFIC GRAVITY OF 1.200 G BOF IN ALL CELLS SPECIFIC GRAVITY OF 1.200 OR MORE @ 80°F WW ALL CELLS REPLACE BATTERY CONNECT 300 AMP LOAD FOR 15 SEC. “SMOKE” IN ONE OR MORE CELLS! =NO_SMOKE” [REPLACE BATTERY T. PLACE THERMOMETER IN ONE CELL 2. APPLY SPECIFIED LOAD LISTED IN” SPECIFICATIONS 13, READ VOLTAGE AT 15 SECONDS WITH LOAD CONNECTED 44, REMOVE LOAD AND READ ELECTROLYTE TEMPERATURE THEN COMPARE VOLTAGE AND TEMPERATURE READINGS WITH CHART BELOW TESS THAN” VOLTAGE [SAME AS OR GREATER] [FULLY CHARGE. CLEAN ADD ON CHART THAN VOLTAGE ON WATER TO SPLIT RING CHART AND RETURN BATTERY TO SERVICE REPLACE BATTERY VOLTAGE AND TEMPERATURE CHART Voltage must not drop below minimum listed at given temperature when battery is subjected to the proper load for 15 seconds and is 1.200 specific gravity @ 80°F or more. MINIMUM VOLTAGES | Electrolyte Temperature Down To: Votage aor | 70°F | aor | 50% | a0 | a0% | 20% | 10% | OF 6Vok | 4.8 48 47 47, 46 45 44 43 42 e-vot | 6.4 64 63 62 61 6.0 5.9 57 5.6 12-Volt | 9.6 96 9.5 94 9.3 91 89 87 85,BATTERY CHARGING GUIDE (6-Volt and 12-Volt Batteries) Recommended Rate* and time for fully discharged condition Rese capocty Twat How SAmperes 10 Amperes «20 Amporen. «20 Ampares 40 Amperes TBuimies SOAS Hour SHows 24f2Hours = 2 Hour Hom Tee Mom gum atom SMe atom Apowe Nee toe Ropere Hours 20 Hours 10 Hours 5 Hours 3 Hours 2172 Hours Hom 101 Aw 1 apg ete TR Noun Stone moowo as snpue ours 20 Hours 10 Hours 6 1/2 Hours 5 Hours “Initial rate for constant voltage taper rate charger To avoid damage charging rate must be reduced or temporarily halted tf: 1, Electrolyte temperature exceeds 125 °F. 2. Violent gassing or spewing of electrolyte occurs. Battery is fully charged when over a two hour period at a low charging rate in amperes all cells are gassing freely and no change in specific gravity occurs. For the most satisfactory charging, the lower charging rates In amperes recommended. Full charge specific gravity is 1.260 - 1.280 corrected for temperature with electrolyte level at split ring.BATTERY SAFETY PRECAUTIONS When working with batteries, use extreme care to avoid spilling or splashing electrolyte, The electrolyte can destroy clothing and cause body burns. If electrolyte is spilled or splashed on clothing or body, It should immediately be neutralized with a solution of baking soda and water then rinsed with clean water. Electrolyte splashed into the eyes is extremely hazardous. Safety glasses should be worn when working with batteries. If electrolyte is splashes into the eyes, force the eye open and flood it with cool clean water for about five minutes and call a doctor immediately. Do not add eye drops or other medication unless advised by the doctor. Hf electrolyte is spilled or splashed on painted or unpainted metal surface of a vehicle, it ‘should be neutralized with the baking soda solution and rinsed with clean water. When batteries are being charged, an explosive gas mixture forms in each cell. Part of this gas escapes through the holes in the vent plugs and may form an explosive atmosphere SFound the battery # ventilation is poor. This explosive gas may remain in of around the battery for several hours after it has been charged, Sparks or flames can ignite this gas causing an intemal explosion which may shatter the battery. The following precautions should be observed to prevent an explosion: 1. Do not smoke near batteries being charged or which have been very recently charges. 2. Do not break live circuits at the terminals of batteries because a spark usually occurs at the points where a live circult is broken. Care must always be taken when connecting or disconnecting booster leads or cable clamps on chargers. Poor connections are a common cause of electrical arcs which cause explosions. Sparks or flames near a battery may ignite explosive gases causing an explosion.