Service manual

RECYCLING IS CRITICAL..
Did you know lead-acid batteries are virtually 100% recyclable? They have a higher recycling rate than other waste products such as aluminum, paper, glass and plastic. Be sure to return your lead-acid batteries to a dealer. In most states it is illegal to discard a battery in the trash.
BE CAREFUL!..
WARNING: Batteries produce explosive gases. Keep sparks, flames, and cigarettes away from batteries at all times. Protect your eyes at all times. Never lean over battery when jumping or performing other maintenance. Remember... always wear safety glasses
when working around batteries!
TYPES OF MARINE / RV BATTERIES ..
The various types of batteries used in Marine and RV service are:
• Maintenance-Free Non-Accessible Engine Starting
with no filler caps
• Low-Maintenance Accessible Starting with filler caps • Dual Purpose (Starting/ Cycling) with filler caps • Deep Cycle with filler caps
You may have one or more of the same type or different types on board your boat or RV. Determine which type of battery or batteries you have and follow the correct set of instructions.
SERVICE TIPS ..
Always wear safety glasses when working around batteries.
Batteries can explode! Protect your eyes. 1. Perform a visual inspection. Inspect for defective or cracked
case and cover, and loose or damaged terminal posts or cables. Replace batter
y and/ or cables immediately if any
damage is found.
DANGER
/
POISON
!
KEEP OUT OF THE REACH OF CHILDREN.
DO NOT TIP. KEEP VENT CAPS TIGHT AND LEVEL.
DO NOT OPEN FLUSH COVER BATTERIES.
SHIELD EYES.
EXPLOSIVE GASES
CAN
CAUSE BLINDNESS
OR INJURY.
NO
•
SPARKS
•
FLAMES
•
SMOKING
SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS.
FLUSH EYES IMMEDIATELY WITH WATER.
GET MEDICAL HELP FAST.
SERVICE TIPS (continued) ..
Look for loose connections or hold-downs. Tighten snugly if appropriate. DO NOT OVER-TIGHTEN TO AVOID BATTERY DAMAGE!
2. Keep the batteries and battery compartment clean and
corrosion free. Dirty, corroded batteries can self-discharge, which will affect performance and life. Clean corrosion with a paste made from baking soda and water. Apply liberally. Any corrosion is neutralized when the solution stops bubbling. Wash off with large quantities of water to avoid environmental damage.
3. Shine lead posts and terminal ends with a wire brush or
steel wool to clean corrosion and assure a low resistance connection. Reassemble and coat lead parts with petroleum jelly or a terminal protection spray. Repaint hold-down, tray and surrounding parts if necessary.
CHECK THE STATE OF CHARGE ..
Always wear safety glasses when working around batteries.
Batteries can explode! Protect your eyes. • MAINTENANCE-FREE NON-ACCESSIBLE TYPES,
WITH NO FILLER CAPS: 1. Check the state-of-charge of the battery with a voltmeter.
If the reading is above 12.4 volts, the battery is at least 75% charged and should be OK. If below 12.4 volts, see the Charging Tips section.
• ACCESSIBLE TYPES, WITH FILLER CAPS:
1. Using a voltmeter: Check the state-of-charge of the
battery. If the reading is above 12.4 volts, the battery is at least 75% charged and should be OK. If below 12.4 volts, see the Charging Tips Section. Or,
2. Using a hydrometer: Check the state-of-charge of the
battery by taking a reading from one cell. Use a different cell each time. If the reading is above 1.225 specific gravity, the battery is at least 75% charged and should be OK. If below 75%, see the Charging Tips section. Be careful of the sulfuric acid in the batter
y. It can
burn eyes, clothing and damage paint and electronic equipment. FLUSH EYES IMMEDIATELY WITH LARGE QUANTITIES OF COOL WATER. GET MEDICAL HELP FAST. Specific gravity readings need to be corrected to 80ºF (27ºC) to allow for temperature of the electrolyte and to insure accurate readings. For each 10 degrees above 80ºF (27ºC), add four points to the hydrometer reading.
CHECK THE STATE OF CHARGE (continued) ..
For each 10 degrees below 80ºF (27ºC), subtract four points to the hydrometer reading. For example, at 90ºF (32ºC) a hydrometer reading of 1.250 would be corrected to 1.254. Likewise, at 70ºF (21ºC) a hydrometer reading of 1.250 would be corrected to 1.246. If the electrolyte level is too low to read with a hydrome- ter, add distilled water as noted below and run the engine or equipment at least two hours to mix the electrolyte and avoid a false reading.
3. Check electrolyte levels in all cells. If necessary,
add distilled water (or clear, odorless drinking water). Do not use water with high iron content to avoid battery damage. Never add acid, only water to a battery. If it will be necessary to charge the battery, bring the levels in all cells to just above the separators inside the cells to allow for expansion during charging. Top off after charg- ing as noted below. If it is not necessary to charge the battery, (or after charging) top off by filling each cell with distilled water to just below the filler tube in each cell.
LOAD TESTING ..
Always wear safety glasses when working around
batteries. Batteries can explode! Protect your eyes. Using a voltmeter or hydrometer will tell you if your battery is charged. But these tests will not indicate if a battery can "hold a load." A battery can be fully charged, but be so weak or worn out that it can no longer perform its function of starting an engine or running accessory loads. Therefore, you must also perform a load test to determine the state of health of your battery. 1. Follow the instructions on the variable load tester or ask
your favorite service dealer to load test your battery.
2. If the battery maintains a minimum "on load" voltage of
9.6 volts for 30 seconds, it is in good condition. If not, recharge and load test again.
3. If it fails a second time, replace the battery
immediately.
RETURN
LEAD
RECYCLE
Pb