- distilled water filling tank;
- densimeter.
Materials needed: distilled water if the electrolyte level in the cells is low.
1. Inspect the battery and make sure that its casing is not damaged.
If the case is damaged, electrolyte may leak, which in turn may cause serious damage to nearby parts. Replace the battery if necessary.
2. Check the strength of the battery in the tray by pushing it from side to side with sufficient force. A poorly secured battery can cause the wires to catch fire or damage the electrical system.
3. Remove the battery cover, if present, by pressing the latch (see arrow in illustration) and moving the lid forward.
4. Check the strength of the battery fastening in the tray by pushing it from side to side with sufficient force. If the battery fits loosely in the tray, tighten the fastening bolt with a force of 20 Nm.
Caution! If the terminal on the positive pole of the battery is loose, remove the terminal of the ground wire (-) from the negative pole before tightening it to avoid a short circuit.
5. Check the strength of the fastening of terminals 1 and 2 of the power wires. If necessary, tighten the fastening nuts, bringing the tightening to 6 Nm (see illustration).
6. Close the battery cover, if applicable.
Checking the electrolyte level
Batteries with indicator and cell plugs
Attention! Indicator 1, called the "magic eye", may be located in a different place (see illustration 29.7). To check the electrolyte level in the cells, it may be necessary to remove the battery cover.
7. Check the electrolyte level and charge level using indicator 1 on the battery, illuminating the indicator with a flashlight (see illustration). The indicator optically displays the battery status and can be colored in one of the three colors listed below.
The color of the indicator is green. The battery is charged sufficiently. The electrolyte level is normal.
The color of the indicator is black. The battery is not charged or the charge is too weak.
The color of the indicator is yellow/colorless. The critical state of the electrolyte has been reached. Be sure to add distilled water.
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Warning! Air bubbles on the indicator may cause the battery condition assessment to be incorrect. In this case, it is recommended to lightly tap the battery case with a suitable object before inspection.
Attention! If the battery life is 5 years or more, and the indicator color is colorless, then it is recommended to replace this battery with a new one.
Since the indicator is located only above one cell, the reading only concerns this cell. An accurate assessment of the battery condition is only possible when testing it under load.
Warning! Do not use open flame to light an open battery (lighter, matches). Explosion possible. The battery should only be illuminated with a flashlight.
Filling with distilled water
8. Turn off the ignition.
9. Remove the foil that covers the cell plugs.
10. Unscrew the plugs 2 using, for example, a HAZET-4650-3 screwdriver (see illustration 29.7).
Attention! In workshops, the VAS-5045 container is used to fill the battery with distilled water (see illustration 29.0). The design of this container does not allow overflow and, accordingly, leakage of electrolyte. As soon as the electrolyte level during filling reaches the maximum permissible level, the supply of distilled water from the specified container automatically stops.
11. Add distilled water up to the MAX mark on the battery case (see arrow in illustration), if there is no filling tank.
12. Add distilled water to the level of the plastic rib 1 in the cell if the electrolyte level cannot be determined from the outside, through the housing (see illustration).
13. Screw in and tighten the plugs.
Attention! Do not pour too much distilled water into the cells, because the electrolyte will spill out and damage nearby parts. If necessary, remove excess electrolyte.
Batteries with indicator and without cell plugs
Attention! The condition of such batteries is checked in the same way as for batteries with plugs. However, in this case, if the electrolyte level is low and the indicator 1 is yellow or colorless, the battery should be replaced (see illustration 29.0a).
Attention! Cover 2 is designed for filling the battery at the manufacturer's plant. It is not allowed to remove it. Otherwise, the battery will be unsuitable for operation (see illustration 29.0a).
Batteries without indicator
14. Check the electrolyte level and add distilled water to the cells if necessary.
15. Check the electrolyte level through the transparent battery case. If the electrolyte level in the battery cells has dropped below the MIN mark, it is necessary to add distilled water (see illustration).
Warning! If the battery case is opaque, unscrew the plugs and check the electrolyte level by looking into the holes. Do not expose the battery to an open flame. Explosion is possible!
16. Turn off the ignition.
17. Add distilled water to each cell up to the MAX mark or to the edge of the plastic rib 1 (see illustration 29.12).
18. Screw in and tighten the plugs.
Attention! Do not pour too much distilled water into the cells, because the electrolyte will spill out and damage nearby parts. If necessary, remove excess electrolyte.
Checking the battery open circuit voltage
19. Turn off the ignition, remove the key from the ignition switch and turn off all on-board electrical system consumers.
20. Disconnect the power wire terminals from the battery terminals.
The open circuit voltage should be measured no earlier than two hours after disconnecting the battery and turning off all consumers.
During this period, the battery should not be recharged or discharged.
21. Connect a combination instrument (voltmeter) to the battery terminals and measure the voltage.
Evaluation of the received readings
12.5V or higher - the battery condition is good. If the voltage below 12.5 V - the battery condition is unsatisfactory. Charge the battery.
If the battery was charged, check the open circuit voltage only two hours after charging is complete.
If the open circuit voltage is still less than 12.5 V after charging the battery, it is recommended to replace the battery.
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