Charging System: Service and Repair

BATTERY CHARGING

1. WARNING:
- Batteries normally produce explosive gases. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery always shield your face and protect your eyes. Always provide adequate ventilation. Failure to follow these instructions may result in personal injury.
- Keep batteries out of reach of children. Batteries contain sulphuric acid. Avoid contact with skin, eyes or clothing. Also, shield your eyes when working near the battery to protect against possible splashing of the acid solution. In case of acid contact with the skin or the eyes, flush immediately with water for a minimum of 15 minutes and seek prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury.
- Always observe all manufacturers instructions when using any charging equipment. Failure to follow this instruction may result in personal injury.
- Connect the charger to the battery before switching the charger on. Failure to follow this instruction may result in personal injury.
- Switch the charger off before disconnecting the charger from the battery. Failure to follow this instruction may result in personal injury.

CAUTION:
- When working on the charging system, be sure to allow the cooling fan to shut off prior to disconnecting the battery. Severe engine damage may result due to a shortened cool-down period for the engine.
- Batteries should not be charged in the vehicle.

NOTE: The maximum level mark is approximately 40 mm below the top of the battery.

Place the battery on a level surface and check the electrolyte level through the casing, to determine if it reaches the indicated maximum mark.

WARNING: It is important not to overfill a battery, as this can cause acid leakage and corrosion damage to the vehicle. Failure to follow these instructions may result in personal injury.

2. If the level is below the maximum mark, remove the vent covers and fill the cell(s) to the correct level.
3. Cold batteries will not readily accept a charge. Therefore batteries should be allowed to warm up to approximately 5°C (41°F) before charging. This may require four to eight hours at room temperature depending on the initial temperature and the battery size.
4. A battery which has been completely discharged may be slow to accept a charge initially, and in some cases may not accept a charge at the normal charger setting. When batteries are in this condition, charging can be started by use of the dead battery switch on chargers that have this feature.
5. To determine whether a battery is accepting a charge, follow the manufacturer's instructions for the charger on the use of the dead battery switch. If the switch is the spring-loaded type, it should be held in the ON position for up to three minutes.

6. NOTE: A rapid recharger procedure has been developed for recharging batteries that have passed the Load Test and only need a recharge. This can be due to in-service no-start battery failures (vehicle will not crank due to low battery state of charge) or battery discharged in vehicle due to key-off loads.

After releasing the dead battery switch and with the charger still on, measure the battery voltage. If it shows 12 volts or higher, the battery is accepting a charge and is capable of being recharged. However, it may require up to two hours of charging with batteries colder than 5°C (41°F) before the charge rate is high enough to show a charge on an ammeter. It has been found that all non-damaged batteries can be charged by this procedure. If a battery cannot be charged by this procedure, a new one should be installed.

7. With the cables then disconnected, the battery can be rapidly recharged by using either of the following methods:
- Carry out a two hour charge using 20 A constant current (manual setting on charger).
- Carry out a two hour charge using a constant potential (automatic selling on charger).