Battery Testing
B. Measure the specific gravity of each cell with a
hydrometer. Fill and drain the hydrometer two to four
times before drawing a sample. At the same time,
take the temperature of the cell.
When testing batteries in the WorkmanMDE, itis impor-
tant to test all batteries. Proper performance of the ve-
hicle depends on all batteries being in good condition.
Testing will determine if one (or more) of the batteries
needs to be replaced.
C. Have enough electrolyte in the hydrometer to
completely support the hydrometer float. Record the
hydrometer reading and return the electrolyte to the
battery cell.
1.
The preferred testing procedure is to use the Lester
Electrical 36/48 Volt Battery Discharge Unit (Model
This instrument puts a known discharge load
Amps) on the battery pack until the battery pack
17770).
(56.25
D. Repeat test for remaining battery cells.
E. Temperature correct each cell reading. For each
reaches 42volts. Atimer incorporated into thedischarg-
ermeasures thetimeneededtoreachthatvoltagelevel.
Battery capacity and remaining life can be determined
from the test results. Refer to Discharge Unit Operating
Instructions for further information.
10
o
F (5.5
specificgravityreading.Foreach10
F (26.7 C) subtract 0.004 from the specific grav-
ity reading.
o
C) above 80
o
F (26.7
o
C) add 0.004 to the
o o
F(5.5 C)below
80
o
o
Example:
Cell Temperature
100oF
Cell Specific Gravity Reading 1.245
Other types of battery load testers can also be used to
test the Workman batteries. Many locally available bat-
tery load testers do not, however, have any adjustment
on the load that is put on the battery. Results received
from using load testers should follow the recommenda-
tions of the load tester manufacturer.
ADD (20o above 80oF)
Correction to 80oF
0.008
1.253
F. The specific gravity of all battery cells should be
1.277 + 0.007. If low cell readings exist (see Fig. 46),
charge battery and take specific gravity readings
again.
2.
If the Lester Battery Discharge Unit (or other load
tester) is not available, an alternate battery test can be
done using a multimeter to perform a voltage test of
each battery. Use the following procedure:
G. If specific gravity of any cells remain low after
complete charging, battery should be replaced.
A. Foraccuratevoltagetesting,allowbatteriestore-
main idle (no charging, no discharging) for at least 6
hours and preferably 24 hours.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
1.277
1.258
1.238
1.217
1.195
1.172
1.148
1.124
1.098
1.073
6.37
6.31
6.25
6.19
6.12
6.05
5.98
5.91
5.83
5.75
B. Open the battery circuit by carefully removing
one of the battery cables (see Opening Battery Cir-
cuit in the General Information section of this chap-
ter). Then, disconnect both cables from battery to be
tested.
C. Measure the battery voltage with the multimeter.
Record battery voltage. The measured voltage will
determine battery state of charge.
D. If voltage readings below 70% charged (see Fig.
46)
exist, charge battery and take voltage measure-
ments again. If voltage remains low after charging,
consider battery replacement.
Figure 46
3.
ic gravity test of the battery electrolyte using a hydrome-
ter. Use the following procedure:
Athirdoptionforbatterytestingistoperformaspecif-
IMPORTANT: Make sure the area around the battery
fill caps is clean before removing the caps.
A. Removebatteryfillercaps.Donotaddwaterprior
to testing specific gravity of battery electrolyte. If
electrolyte level is low, add distilled water and
charge battery before performing specific gravity
test.
Workman MDE
Electrical System
Page 3 -- 31
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