Battery Charging

WARNING: DO NOT CHARGE A BATTERY THAT HAS EXCESSIVELY LOW ELECTROLYTE LEVEL. BATTERY MAY SPARK INTERNALLY AND EXPLODE. EXPLOSIVE GASES FORM OVER THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR BATTERY. DO NOT ASSIST BOOST OR CHARGE A FROZEN BATTERY. BATTERY CASING MAY FRACTURE. BATTERY ACID IS POISON, AND MAY CAUSE SEVERE BURNS. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF REACH OF CHILDREN.

Disconnect Battery Negative Cable:

CAUTION: Disconnect the battery NEGATIVE cable first before charging battery to avoid damage to electrical systems. Do not exceed 16.0 volts while charging battery. Refer to the instructions supplied with charging equipment

NOTE: The battery cannot be refilled with water, it must be replaced.

A battery is considered fully charged when it will meet all the following requirements.
- It has an open circuit voltage charge of at least 12.4 volts. Refer to Battery Open Circuit Voltage table within Battery Open Circuit Voltage Test.
- It passes the 15 second load test, refer to the Load Test Temperature chart.

Reading Test Indicator:

- The built in test indicator dot is GREEN.

Battery electrolyte will bubble inside of battery case while being charged properly. If the electrolyte boils violently, or is discharged from the vent holes while charging, immediately reduce charging rate or turn off charger. Evaluate battery condition. Battery damage may occur if charging is excessive.

Some battery chargers are equipped with polarity sensing devices to protect the charger or battery from being damaged if improperly connected. If the battery state of charge is too low for the polarity sensor to detect, the sensor must be bypassed for charger to operate. Refer to operating instructions provided with battery charger being used.

CAUTION: Charge battery until test indicator appears green. Do not overcharge.

It may be necessary to jiggle the battery or vehicle to bring the green dot in the test indicator into view.

After the battery has been charged to 12.4 volts or greater, perform a load test to determine cranking capacity. Refer to Battery Load Test. If the battery passes the load test, return the battery to use. If battery will not endure a load test, it must be replaced. Properly clean and inspect battery hold downs, tray, terminals, cables, posts, and top before completing service.

Battery Charging Timetable:

Battery Charging Time Required

WARNING: NEVER EXCEED 20 AMPS WHEN CHARGING A COLD -1°C (30°F) BATTERY. PERSONAL INJURY MAY RESULT.

The time required to charge a battery will vary depending upon the following factors.

Size Of Battery
A completely discharged large heavy-duty battery may require more recharging time than a completely discharged small capacity battery, refer to the Battery Charging Timetable for charging times.

Temperature
A longer time will be needed to charge a battery at -18°C (0°F) than at 27°C (80°F). When a fast charger is connected to a cold battery, current accepted by battery will be very low at first. In time, the battery will accept a higher rate as battery temperature warms.

Charger Capacity
A charger which can supply only five amperes will require a much longer period of charging than a charger that can supply 20 amperes or more.

State Of Charge
A completely discharged battery requires more charging time than a partially charged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current amperage will be low. As water is converted back to sulfuric acid inside the battery, the current amp rate will rise. Also, the specific gravity of the electrolyte will rise, bringing the green ball into view at approximately 75 percent state-of-charge.