LESSON 5

You should check the electrolyte level in each cell to ensure the lead plates are fully submerged. This is important because low electrolyte levels expose the plates to air, which causes sulfation and reduces the battery’s capacity. To perform this task, refill the cells only with distilled water never use tap water and fill to the manufacturer-recommended level without overfilling, as this can cause overflow during charging. 

VOLTAGE AND SPECIFIC GRAVITY TESTING:

Measure the battery’s voltage and the specific gravity of the electrolyte to identify weak cells, imbalanced charging, or failing batteries. Use a digital voltmeter to check the voltage levels and a hydrometer to measure specific gravity (this is only applicable for flooded batteries). A fully charged battery typically has a specific gravity ranging from 1.265 to 1.299.

VISUAL INSPECTION FOR DAMAGE AND LEAKAGE:

Inspect the battery casing regularly for any cracks, bulges, or signs of acid leaks. Physical damage to the battery can compromise both safety and functionality. Conduct these inspections during every maintenance cycle and address any issues promptly. 

TEMPERATURE CONTROL AND ENVIRONMENT MONITORING:

Inspect the battery terminals and cable connections regularly for any signs of corrosion or buildup. Corrosion increases electrical resistance, which reduces charging efficiency. To clean the terminals, use a mixture of baking soda and water along with a wire brush, then apply a protective coating such as petroleum jelly or a terminal spray to prevent future corrosion.

EQUALIZATION CHARGING:

Periodically perform an equalization charge, which is a controlled overcharge designed to balance the cells, de-stratify the electrolyte, and remove sulfate buildup. This should be done using a charger with an equalization setting, following the manufacturer’s recommendations usually every 30 to 90 days depending on usage. 

MAINTAINING PROPER CHARGE LEVELS:

Ensure that batteries are charged regularly and never left in a deeply discharged state, as this can cause sulfation and permanent capacity loss. Use a charger appropriate for the specific battery type, applying the correct voltage and amperage settings.