Troubleshooting
In general, troubleshooting will be done for two distinct reasons. First, a battery that performs poorly and is
outside of the manufacturer’s specifications should be identified in order to replace it under the terms of the
manufacturer representative for specific requirements.
The second reason is to determine why a particular vehicle does not perform adequately. Performance problems
may result in a vehicle that runs slowly or in a vehicle that is unable to operate for the time required.
A new battery must mature before it will develop its maximum capacity. Maturing may take up to 100 charge/
discharge cycles.
After the maturing phase, the older a battery gets, the lower the capacity. The only way to determine the capacity
of a battery is to perform a load test using a discharge machine following manufacturer’s recommendations.
A cost effective way to identify a poorly performing battery is to use a hydrometer to identify
a battery in a set
with a lower than normal specific gravity. Once the particular cell or cells that are the problem are identified, the
suspect battery can be removed and replaced. At this point there is nothing that can be done to salvage the
battery; however, the individual battery should be replaced with a good battery of the same brand, type and
approximate age.
Hydrometer
A hydrometer is used to test the state of charge of a battery cell. This is performed by measuring the density of
the electrolyte, which is accomplished by measuring the specific gravity of the electrolyte. The greater the
concentration of sulphuric acid, the more dense the electrolyte becomes. The higher the density, the higher the
state of change.
WARNING!
To prevent battery explosion that could result in severe personal injury or death, never insert a metal thermometer
into a battery. Use a hydrometer with a built in thermometer that is designed for testing batteries.
Battery Filling Systems
Batteries should only be filled after charging
Personal protective equipment should be worn during installation and watering
Do not store hand pump in battery compartment
STEP 1: FULLY CHARGE THE BATTERIES
This must be done before water is added to the batteries to avoid electrolyte loss.
STEP 2: FILLING WITH A MANUAL PUMP
Insert the manual pump assembly end into a jug of distilled water.
STEP 3: ATTACH WATER SUPPLY LINE
Remove the dust cap from the watering system fill tube. Connect it to the manual pump connector by inserting it
into the quick connect.
STEP 4: FILL BATTERY WITH WATER
Squeeze the bulb on the manual pump to begin filling the battery cells with water. When the bulb becomes hard,
and the valve indicator eyes have risen, all of the cells are full.
STEP 5: DISCONNECT
Disconnect the manual pump connector from the watering system and replace the dust cap.
WARNING!
NEVER LEAVE WATERING SYSTEM CONNECTED TO MANUAL PUMP OR ANY OTHER FILLING DEVICE!
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