Battery, charging
CAUTION:
- Prior to handling or servicing batteries, read, understand and observe the Warning and Safety Measures for lead-acid batteries Smoking, naked flames, fires and sparks: .
- Always wear suitable protective clothing Eye protection and protective clothing: .
Danger of explosion!
- Batteries produce explosive gasses while being charged.
- Keep open flames and sparks away and DO NOT smoke near batteries.
- The battery charger MUST be turned off when connecting or disconnecting the cables at the battery.
- Battery cell caps must NOT be removed while charging.
- "Boosting" a sulfated battery a high charging rate can cause an explosion.
- Ensure that battery is charged in a well ventilated area.
- Precision tools must not be kept in the same room where batteries are being charged. Tools may corrode due to chemical reaction.
Special tools, testers and auxiliary items required
- Battery Charging Station: Midtronics INC-940.
NOTE:
- Before charging, battery must have a minimum temperature of 10 degrees Celsius (50 degrees Fahrenheit).
- It is not necessary to remove battery from vehicle or disconnect battery terminals.
- Charging voltage must not exceed 14.4V.
- Always follow the battery charger operating instructions.
- After charging, confirm battery no load voltage and electrolyte specific gravity before reuse in vehicle.
CAUTION:
Before beginning repairs on electrical system
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.
- Slide battery cover to right - arrow 1 - and lift off - arrow 2 - where applicable.
Battery in engine compartment:
- Connect battery charger to battery, positive to positive ( + ) - 2 - , negative to negative ( - ) - 1 -.
Battery in engine compartment:
- Release retaining clamps - arrow - and open cover - 2 - over positive terminal.
- Connect positive battery charger clamp - 3 - to positive ( + ) terminal - 4 - and to negative battery charger clamp - 5 - to negative terminal - 1 - (VAS 5900 charger shown for illustration purposes only).
All:
- Switch on battery charger.
CAUTION:
If battery begins gassing (boiling) violently when charging, REDUCE charging rate immediately.
- Adjust charging rate according to battery capacity (refer to Midtronics INC-940 Instruction Manual).
Charging totally discharged batteries
- Batteries which have not been used for lengthy periods, e.g. in vehicles which have not been driven, are subject to self-discharge.
- A battery is considered to be totally discharged if the no-load voltage has dropped below 11.6 V. Initial battery damage can occur between 12.2 and 11.6 V. Measuring no-load voltage → No-load voltage, checking .
- In a totally discharged battery the electrolyte (sulfuric acid/water mixture) is reduced to almost all water, as the sulfuric acid content is heavily reduced. At temperatures below zero, the battery may freeze and the cause the housing to burst.
- Totally discharged batteries become sulphated, i.e. all the plate surfaces of such batteries become hard. The electrolyte has a slightly milky appearance (instead of being clear).
- If totally discharged batteries are charged directly after being discharged, the sulphation dissipates.
- If this is not done, the plates become even harder and their ability to absorb charge is impaired. This results in reduced power output.
Procedure for charging exhausted batteries (sulphated)
Totally discharged batteries (that are also sulphated) must be charged as follows using a low charging current:
- Set charging current to approx. 5 % of battery capacity, i.e. for a 60 Ah battery the charging current is approx. 3 A.
- Charging battery → Battery, charging .
- The charging voltage (U max ) must not exceed 14.4 V.
CAUTION:
Never "quick charge" a totally discharged battery. Effective charging will not take place, despite what appears to be a sufficient voltage applied. Batteries loaded in this manner may be incorrectly evaluated as OK and battery damage may result.