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Section 5 - ADJUSTMENTS & REPAIR
Battery Condition Chart
State of Charge Syringe Hydrometer Digital Voltmeter Five Ball Hydrometer
100% Charged w/ Sulfate Stop 1.280 12.80v Five Balls Floating
100% Charged 1.265 12.60v Four Balls Floating
75% Charged 1.210 12.40v Three Balls Floating
50% Charged 1.160 12.10v Two Balls Floating
25% Charged 1.120 11.90v One Ball Floating
0% Charged Less than 1.100 Less than 11.80v Zero Balls Floating
4.7.4. BATTERY TESTING
There are two types of battery tests: Unloaded and
Loaded. The unloaded test is the procedure that will
be discussed. It’s the simplest and most commonly
used. An unloaded test is made on a battery without
discharging current. To perform unloaded testing,
check charge condition using either a hydrometer or
voltmeter.
1. Using a voltmeter, voltage readings appear
instantly to show the state of charge. Remember to
hook the positive lead to the battery’s positive
terminal, and the negative lead to the negative
terminal.
2. A hydrometer measures the specific gravity of
each cell. The specific gravity tells the degree of
charge; generally, a specific gravity of about 1.265
to 1.280 indicates full charge. A reading of 1.230 to
1.260 indicates the battery should be charged
before testing. The Battery Condition Chart shows
the charge level as measured by syringe float
hydrometer, digital voltmeter and five ball
hydrometer.
4.7.5. NEW BATTERY PREPARATION
1. Remove battery from carton.
2. Place battery in a well ventilated area on a level
non-concrete surface.
3. Remove battery cell caps. Fill cells as required
with electrolyte (purchased separately) to proper
level. Fill to 3/16” above cell plates. Filling battery
with electrolyte will bring the battery to 80% charged
state.
4. With cell caps removed, connect battery charger to
battery terminals; RED to positive (+) and BLACK to
negative (-) terminal.
IMPORTANT: 3/16” above cell plates is the
recommended level. DO NOT place anything in battery
other than specified electrolyte.
WARNING
DO NOT OVERFILL!
WARNING
DO NOT attempt to service or charge the battery
while it is installed in the machine. DO NOT use
“BOOST” chargers on the battery.
5. Slow charge the battery at 1 amp for 2 hours to
bring the battery to full charge.
6. After charging, check level of electrolyte and
add as needed to bring level to 3/16” above cell
plates.
7. Reinstall cell caps.
8. Install battery into power unit.
9. Connect positive (+) cable (red) first, from
wiring harness to the positive terminal (+) on
battery using bolt and nut provided in hardware
bag. Connect negative (-) cable (black) last, to
negative terminal (-) on battery using bolt and nut.
Apply a small amount of grease over terminals to
prevent corrosion.
10. Install battery retainer and positive terminal
cover.
WARNING
Shield the positive terminal with terminal cover
located on battery harness. This prevents metal from
touching the positive terminal which could cause
sparks. Cables must be connected to battery
terminals in the proper position. RED (Positive) cable
must go to the ( + ) terminal. BLACK (Negative) cable
must go to the ( - ) terminal.