Installation Manual

43
• Battery Terminal has melted
• This is most common with loose connections, causing a highly resistant
connection. This resistance has caused heat buildup and melted the
terminal connection.
• This can be caused by:
• Loose connections
• Over-tightened connections
• Improper sized cables (too small).
• Corroded connections
• Improper use of washers/lock washers.
• Too many connections on the same terminal
• Battery cover has cracked, shattered and/or dislodged from the case
(Not affecting positive and negative terminals or connections)
• Ignition of hydrogen gas may have caused the battery cover
to crack or explode.
• This sometimes occurs during a charge where a loose connection
at the terminal sparked, igniting hydrogen gas from the cell.
• This may be the result of low electrolyte levels causing high cell
temperature and increased hydrogen gas. Check each dell and top
up with distilled water as necessary.
• Battery case has split or cracked originating from the sides.
• The battery may have frozen in the past, which has weakened
the case structure.
• Battery and/or cell(s) do not require watering.
• The battery may have a cell that has failed and no longer accepts a charge.
1. Verify specific gravity of all cells and voltage reading of
each battery.
2. Perform a load test to identify any cell failures and verify
proper cell operation.