Electrolyte Level, Checking

Electrolyte Level, Checking

WARNING:
- Always heed accident prevention regulations when handling electrolyte.
- Always wear suitable protective clothing.
- Use a light to illuminate inside of battery casing.
- Never illuminate inside of battery casing with an openflame.
- Keep open flames and burning cigarettes away from batteries.
- When disposing of batteries, always observe the appropriate regulations for batteries and sulfuric acid.
- It is essential that genuine and proper battery sealing plugs be used to ensure differing battery cover systems are sealed correctly. Use genuine sealing plugs of same construction if lost or damaged.
- The plugs must be installed with an O-ring seal.

Special tools and equipment







- Battery filler VAS 5045
- Hydrometer, commercial type

NOTE:
- The correct battery electrolyte level is an important factor in ensuring long life of battery.
- If batteries are provided with clear visible min. and max. marks, it is sufficient to check electrolyte level by a visual inspection of battery.
- The electrolyte level must be above min. mark but not exceed max. mark.
- If external min. and max. marks on a battery are not readily visible, or if electrolyte level cannot be checked properly due to an opaque battery casing, battery caps must be unscrewed. It is then possible to check electrolyte level by performing a visual internal check of battery.
- The electrolyte level must be in line with internal electrolyte level mark (plastic web). This is equivalent to external max. mark.







- On batteries with the charge indicator -arrow-, electrolyte level can be read from color indicator.
- Test sequence. Battery With Charge Indicator


Electrolyte level too low

NOTE: If electrolyte level is too low, cell plates will dry out and battery will lose power. The cell plates must be fully covered by electrolyte (sulfuric acid/water mixture) in order to prevent corrosion of plates, plate bridges and cell connectors. The function of the battery is not guaranteed and it becomes unusable.







- If electrolyte level is too low, top off to max. mark with distilled water using battery filler VAS 5045.

NOTE:
- The filler neck of the filler VAS 5045 is designed to prevent over-filling of the battery cell and electrolyte leakage. The flow of distilled water into the battery cell is interrupted on reaching the max. level.
- Always use distilled water for topping off to prevent electrolyte contamination which results in increased self-discharge.

- Re-insert all battery cell sealing plugs; Batteries with central gas venting.

Electrolyte level too high

NOTE: If electrolyte level is too high, leaking electrolyte (sulfuric acid/water mixture) will cause damage outside battery, i.e. to components in engine compartment.







- If electrolyte level is too high (overfilled), i. e. if level is above inside mark (plastic web) or above outer max. mark, electrolyte must be drawn off using a commercially available hydrometer.
- Extract electrolyte using hydrometer until remaining fluid is level with plastic indicator web or max. mark.
- Re-insert all battery cell sealing plugs; Batteries with central gas venting.