Battery Inspection & Maintenance

Proper battery inspection and maintenance are essential for maximizing battery performance, extending service life, and preventing unexpected failures. Follow the recommended inspection, testing, and charging practices to keep your battery operating at peak efficiency.

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BATTERY CARE GUIDE

Why Regular Battery Inspection Matters

A well-maintained battery delivers better performance, longer service life and improved reliability. Regular inspections help identify potential issues before they become costly problems, reducing the risk of breakdowns and premature battery replacement.

Longer Battery Life

Regular checks and proper service life

Reliable Performance

Reliable starts in all conditions

Important Safty

Catch problems before they worsen

Lower Ownership Cost

Avoid costly replacements

Battery Inspection & Maintenance

Check the battery's state of charge.

Check the battery's specific gravity, using a State of Charge Indicator or use of hydrometer.

Ensure the battery is clean, dry and free of dirt and grime.

Check the battery posts and cables for breakage, corrosion or loose connections.

Apply a thin coating of high temperature grease to posts and cable connections for added protection.

Inspect the battery case for bulging signs of physical damage or leaks.

Check the battery electrolyte level. If the level indicates the battery has low electrolyte.

It is important to check if the battery has a lot of corrosion electrode covering the battery plates.

Do not using distilled demineralised water and never use tap water.

When servicing a sealed maintenance free (SMF) battery, check the State of Charge Indicator. This gives you the battery's condition.

If the State of Charge Indicator advises "Replace Battery", it is important that the battery is replaced below the plates which can lead to an internal explosion.

For batteries sealed, sealed overfill and premature water loss by storing in a cool, dry place of charge or voltage display.

Should the voltage be below 12.0V replace the battery.

Battery Testing Methods

Hydrometer

The state-of-charge of a lead acid battery can be determined by the specific gravity (SG) of the electrolyte (its density) compared to water.
The SG can be measured directly with a hydrometer or indirectly by the floating voltage. Please note the temperature of the acid.

Digital Battery Tester / Conductance Meter

Microprocessor controlled digital battery testers are easy to use.
With a battery rating and all battery state data measured the tester works by measuring a small signal through the battery that uses measurements of conductance or resistance (impedance).

Load Tester

Adjustable load testers are a reliable method to determine the starting capacity of a battery as the test applies a real load similar to the actual application.
The meter readings can be read like the battery open circuit voltage or voltage drop observed while load testing.

CHARGING GUIDE

Battery Charging

Charge a lead acid battery in the process of restoring the energy removed during discharge.
Use suitable charging method.
High charge rates should be avoided.
The amount of energy necessary for a full charge depends on the depth of discharge.
Typically 110% - 150% of the discharged ampere-hours depending on battery type.
The charger must be removed or set on float charging mode once the battery is fully recharged.
Never leave the battery on charge longer than necessary to achieve full recharge.

CHARGING SYSTEMS

Charger Selection

Lead acid batteries should be charged in 3 stages: constant current (boost), constant voltage (absorption) and float charge.

Flooded Batteries

Flooded, Absorbed Glass Mat (AGM) and Gel battery type require different charging specifications.

AGM Batteries

Performance and service life.

Deep Cycle Batteries

Monitoring battery voltage during charging is extremely important to avoid premature ageing or failure.

Maintenance Charging

Slow charging is the best way to average (sulfate) a battery used in long term storage.

Recommended Charging Guide

The recommended temperature during charging is 25°C. Charging must be paused if the battery reaches 50°C.

The above specifications are for 12 volt lead acid batteries. When charging 6 volt batteries, half the voltage specifications provided.

In addition to following the battery charging voltage guidelines, selecting the correct charging current (Amps) for the battery size is crucial for optimal performance and service life.

The recharging duration is difficult to determine due to variables such as:

Depth of discharge
Temperature
Size and efficiency of the charger
Age and condition of the battery
For a guide, refer to the content of current charging method table

Important Note

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Factors Affecting Battery Life

High Temperatures

As batteries age they gradually lose their capacity so their function is shortened. The constant charge and discharge eventually leads to failure.

Vibration

Components corrode over time, electrical shorts occur and vibration causes damage, all eventually causing failure.

Overcharging

Overcharging and undercharging of a battery will also have a bearing on battery life.

Undercharging

Undercharging of a battery will also have a bearing on battery life.

Battery Inspection

Check electrolyte level - fluid below the top of the separators indicates overcharging or poor maintenance.
Overcharge condition may be due to incorrect voltage setting, low voltage caused by heat or internal defects, or old age deterioration.
Is there discoloration on the top of the battery? This can indicate overcharging or overfilling.
Is the battery loose in the carrier? This can cause electric short.
Does the battery leak or shows signs of damage or overheating? This can cause failure.

Discharged Batteries (Dead/Flat)

A flat battery should be checked with a hydrometer. A low Specific Gravity reading of 1.120 or less in all cells indicates a discharged battery and it must be charged before further examination and testing can occur.

The discharged condition may be due to a problem in the electrical system (blowing alternator belt, faulty regulator or alternator).
Inspect the cable connections. Check the terminals and connectors.
Internal shorts may also be due to manufacturing defects or overheating.
If the flat battery has been due to normal usage it will now need to be recharged.