Non Maintenance Free Battery, without a Visual Indicator
Non Maintenance Free Battery, without a Visual Indicator
=> [ Central Venting System ]
=> [ Battery Post/Terminal ]
=> [ Testing ]
=> [ Visual Check ]
=> [ Electrolyte Level, Checking ]
=> [ Acid Density, Measuring ]
Lead acid batteries that are non maintenance free are filled with electrolyte fluid (wet battery). They have sealing plugs.
Risk of injury from direct exposure to battery acid!
• Observe the warning notes and safety precautions. Refer to => [ There is a risk of injury from the
battery acid. ] Lead Acid Battery Warnings and Safety Precautions.
Risk of explosion due to the explosive gas that forms during battery charging.
• Observe the warning notes and safety precautions. Refer to => [ Risk of explosion due to the explosive
gas that forms during battery charging. ] Lead Acid Battery Warnings and Safety Precautions.
Central Venting System
To prevent the gas that results from battery charging from causing damage or putting your health at risk, the gas is discharged centrally through an opening on the side of the top cover on the battery.
- Make sure the central venting hose or tube is always secured on the battery.
- Make sure the central venting hose or tube is not pinched. Only then can the battery be properly vented.
• Newer generation batteries have a fine mesh flame trap at the central venting exit point. The flame trap is a round fiberglass mat approximately 15 mm wide and 2 mm thick that works like a valve. On the one hand, it allows the gas formed during battery charging to vent and on the other hand, prevents the explosive gas in the battery from igniting.
Battery Post/Terminal
To prevent damage to the battery terminals and battery housing, observe the following:
• Battery terminals must not be greased.
• Battery terminal clamps - arrows - must only be installed by hand without applying force.
• Install battery terminal clamps so the terminal is flush with the clamp or protrudes out of it.
• After tightening the battery terminal clamps to the specified torque, the threaded connections must not be tightened again.
Testing
Risk of injury and explosion!
• Observe the warning notes and safety precautions. Refer to => [ Lead Acid Battery Warnings and Safety Precautions ] Lead Acid Battery Warnings and Safety Precautions
Perform Battery Checks in the Following Sequence:
- Check the battery electrolyte level.
- Battery testing with the battery tester (VAS 6161), refer to => [ Battery Testing, using VAS 6161 ] Battery Testing, using VAS 6161 or with the battery tester with printer (VAS 5097A), refer to => [ Battery Testing, using VAS 5097A ] Battery Testing, using VAS 5097A or measure the battery acid density.
- Additional procedures depends on the result of the battery test with the battery tester.
Visual Check
- Before performing extensive measurements, inspect visually.
• External battery condition;
• Battery connections;
• Secure battery seating.
Risk of explosion, inadequate crash safety, risk of corrosion, shortened service life.
• A loose battery retaining bracket can damage the battery housing and allow battery acid to leak.
• A battery that is mounted incorrectly can sustain vibration damage resulting in damage to the battery plates.
• Tighten retaining bracket bolt to specification.
Risk of malfunction in the electrical system or wiring burn.
• The wiring connection contact is not guaranteed if the battery terminals are damaged or the battery terminal clamps are loose. Check the condition of the battery terminals; battery terminal clamp and auxiliary clamp tightening specifications.
• Risk of corrosion due to leaking battery acid.
• To ensure that the various battery connection systems are free of leaks, the battery's original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.
• The sealing plugs must be equipped with an O-ring.
Electrolyte Level, Checking
Procedure
Maintaining the correct electrolyte level in the battery is an important factor affecting the length of the battery's service life.
Risk of injury from direct exposure to battery acid.
• Follow accident prevention regulations when working with battery acid. Refer to => [ There is a risk of injury from the
battery acid. ] Lead Acid Battery Warnings and Safety Precautions.
• Wear protective eye-wear and clothing. Refer to => [ Protect against injury by using
protective eye-wear and clothing. ] Lead Acid Battery Warnings and Safety Precautions.
Risk of explosion due to open flame, fire and smoking.
• Only illuminate the inside of the battery housing with a flashlight.
• Never illuminate the inside of the battery housing with an open flame.
• Never handle open flame or burning cigarettes near batteries.
- If the "Min" and "Max" marks on the outside of the battery can be seen, simply inspect by sight.
• The electrolyte level must be above the "Min" mark but must only go as high as the "Max" mark.
- If it is difficult to see the "Min" and "Max" marks on the outside of the battery or they cannot be seen because the battery housing is opaque, remove the sealing plugs.
- Check the electrolyte level by visually checking the inside of the battery.
• The electrolyte level must coincide with the internal level mark (plastic web). This corresponds to the outer "Max" mark.
Risk of corrosion due to leaking battery acid.
• To ensure that the various battery connection systems are free of leaks, the battery's original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.
• The sealing plugs must be equipped with an O-ring.
• If the acid level is too low, the battery must be replaced. Do not add distilled water.
- Install the sealing plugs for the battery cells.
Acid Density, Measuring
Special tools, testers and auxiliary items required
• Refractometer (T10007) or
• Commercially available Hydrometer
Procedure
In conjunction with the battery testing using the battery tester (VAS 6161), refer to => [ Battery Testing, using VAS 6161 ] Battery Testing, using VAS 6161 or the battery tester with printer (VAS 5097A), refer to => [ Battery Testing, using VAS 5097A ] Battery Testing, using VAS 5097A, the acid density test provides information about the condition of the battery.
• The temperature of the battery acid must be at least 10 °C (50 °F).
Risk of injury from direct exposure to battery acid.
• Follow accident prevention regulations when working with battery acid. Refer to => [ There is a risk of injury from the
battery acid. ] Lead Acid Battery Warnings and Safety Precautions.
• Wear protective eye-wear and clothing. Refer to => [ Protect against injury by using
protective eye-wear and clothing. ] Lead Acid Battery Warnings and Safety Precautions.
• Specific density of the electrolyte can be checked immediately after charging battery.
- Remove all sealing plugs from the battery cells.
- Insert the hydrometer into the battery cell and siphon off enough electrolyte until the float floats freely in electrolyte.
• The higher the specific weight of the siphoned battery acid, the higher the float will float.
• The acid density of the electrolyte can be read off in kg/dm3 on the hydrometer scale (specific density of the battery acid).
- Compare the hydrometer reading to the values given in the tables.
Specific acid density must be at least 1.24 kg/dm3 in moderate climate zones. If the acid density in all battery cells is too low:
- Charge the battery and repeat the acid density test.
- If the specified values are not reached, replace the battery.
• The measured values for the specific density of the individual battery cells must not deviate by more than 0.03 kg/dm3, otherwise the battery should be replaced.
Risk due to leaking battery acid.
• To ensure that the various battery connection systems are free of leaks, the battery's original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.
• The sealing plugs must be equipped with an O-ring.
- If the specified values are reached, reinstall the sealing plugs for the battery cells.
• If the battery must be replaced, follow the disposal regulations. Refer to => [ Pollution risk. ] Lead Acid Battery Warnings and Safety Precautions.