Section 06: ELECTRICAL
PA1593
14
3.5 BATTERY MAINTENANCE
Please consult “Deka Group 8D Commercial
Battery Care And Maintenance” document
included with the OEM publications for specific
information concerning battery care and
maintenance, load testing and charging tips for
group 8D battery.
3.5.1 Visual Inspection
1. Check the outside of the battery for a broken
or cracked cover or case that could permit
loss of electrolyte. If obvious physical
damage is noted, replace the battery.
2. Check for loose terminal posts, cable
connections, damaged cables, and for
evidence of corrosion. Correct conditions as
required before proceeding with tests.
The external condition of the battery and the
battery cables should be checked periodically.
The top of the battery should be kept clean and
the battery hold-down clamp bolts should be
kept properly tightened. For best results when
cleaning the battery, wash first with a diluted
solution of ammonia or soda to neutralize any
acid present then wash out with clean water.
The battery fixing clamp bolts should be kept
tight enough to prevent the batteries from
moving, but they should not be tightened to the
point that excessive strain is placed on the
battery (proper tightening torque: 43 lbf-ft).
To insure good contact, the battery cable ring
terminals should be tight on the side terminal
battery adapter. If the terminals are corroded,
the cables should be disconnected and the
posts and clamps cleaned separately with a
soda solution and a wire brush. Install cable ring
terminals on side terminal battery adapter and
tighten to a torque of 13 lbf-ft.
3.5.2 Removing Surface Charge
Disconnect cables from the battery and attach
alligator clamps to the contact lead. Connect a
300 ampere load across the terminal for 15
seconds to remove surface charge from the
battery.
3.5.3 Testing Battery Cables
Check all cable ring terminals and connections
to determine if they are in good condition.
Excessive resistance, generally caused by poor
connections, produces an abnormal voltage
drop which may lower voltage at the starter to
such a low value that normal operation of the
starter will not be obtained. An abnormal voltage
drop can be detected with a low-reading
voltmeter as follows:
DANGER
To prevent the engine from starting during
these tests, remove fuses F91 and F99
located in the VECR of the rear electrical
compartment. Once the tests are completed,
reinstall F91 and F99.
1. Check voltage drop between grounded
(negative) battery terminal and vehicle
frame by placing one prod of the voltmeter
on the battery terminal and the other on a
good ground (unpainted surface) on the
vehicle. With the starter cranking the engine
at a temperature of 70ºF (21ºC), voltage
reading should be less than 0.3 volt. If the
voltage reading exceeds 0.3 volt, there is
excessive resistance in this circuit.
2. Check voltage drop between the positive
battery terminal and the starter positive
terminal stud while the motor is operated. If
the reading is more than 2.5 volts, there is
excessive resistance in this circuit.
NOTE
If it is necessary to extend the voltmeter lead
for this test, use a #16 (AWG) or larger wire.
3. Check voltage drop between the starter
housing and a good ground on the vehicle.
The reading should be less than 0.2 volt.
DANGER
Any procedure other than the following could
cause personal injury or damages to the
charging system resulting from battery
explosion or electrical burns.
Wear adequate eye protection when working
on or near the batteries. Ensure that metal
tools or jumper cables do not contact the
positive battery terminal (or a metal surface in
contact with it) as a short circuit will result. Do
not attempt to jump start a vehicle suspected
of having a frozen battery because the battery
may rupture or explode. Both the booster and
discharged batteries must be treated carefully
when using jumper cables. Follow exactly the
procedure outlined later in this section, being
careful not to cause sparks.
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