Users Guide

TROJAN BATTERY

08 Trouble-Shooting

These battery testing procedures are guidelines only for identifying a deep-cycle battery that may need

to be replaced. Unique situations may be observed that are not identied within this procedure. Please

contact Trojan Battery Company’s technical support engineers at 800-423-6569 Ext. 3045 or +1-562-236-

3045 for help interpreting the test data.

8 .1 Preparation for Testing

î Check that all vent caps are secured properly on the battery.

î Clean the top of the battery, terminals and connections with a cloth or brush and a solution of baking

soda and water (1 cup of baking soda to 1 gallon of water). Do not allow cleaning solution to get

inside the battery. Rinse with water and dry with a clean cloth.

î Check battery cables and connections. Replace any damaged cables. Tighten any loose connections

with an insulated wrench. Refer to Torque Values Section 3.5.

î For deep-cycle ooded/wet batteries, check the electrolyte level and add water if necessary. Refer to

Watering Section 4.2.

î Ensure batteries are fully charged before discharge testing to obtain accurate results.

8.2 On-Charge Voltage Testing

î Disconnect and reconnect DC plug to restart charger.

î While the batteries are on-charge, record the current in the last ½ hour of charge cycle (if possible),

and measure the battery set voltage.

î If the current at the end of the charge is below 5 amps, and the battery set voltage is above the

following readings, proceed to the next step:

î 56V for a 48V system

î 42V for a 36V system

î 28V for a 24V system

î 14V for a 12V battery

î 9.3V for a 8V battery or 7V for a 6V battery

î If the current at the end of the charge does not match these readings, check the charger for proper

output and recharge the batteries. If the set voltages are still low, you may have a failed battery.

î While the batteries are on-charge, measure the individual battery voltages.

î If any battery voltage is below 7V for 6V battery, 9.3V for 8V battery and 14V for 12V battery, and a

voltage variation is greater than 0.5V for 6V battery or 1.0V for a 12V battery, from any other

battery in set, it may be a failed battery.