Safety Precautions

Safety Precautions

During recharging process, batteries release explosive gases. Therefore adequate ventilation systems are needed in all charging areas. When working on or near batteries, always wear protective glasses.

Batteries generate hydrogen, a highly flammable gas. Keep all sorts of combustion producing elements such as sparks, flames, cigarettes, welding, friction and electrostatic discharge away from batteries at all times. Otherwise the hydrogen gas may inflame and explode.

Disconnect the negative (-) polar cable first for dismounting a battery from your vehicle and connect positive (+) polar cable first for mounting.

Do not connect or disconnect "live" circuits. To avoid creating sparks, always turn charging and testing equipment off before attaching or removing clamps.

Do not tilt wet-cell/flooded batteries more than 45 degrees. These batteries contain a solution of sulfuric acid which may cause severe burning of the skin. In the case of contact, clean the affected area with plenty of water and soap. If your eyes are affected, flush out with water and immediately seek medical help.

Never attempt to charge a frozen battery; allow it to warm up to 15 degrees C before placing on charge.

Do not connect the battery before checking the voltage level. Keep all batteries out of reach of children.

Carefully read and comply with the instructions provided by the owner's manual.

For jump starting using booster cables, first connect one end of positive (+) booster cable to positive (+) terminal of discharged battery; connect other end of positive (+) booster cable to positive (+) terminal of assisting battery. Then, connect one end of negative (-) booster cable to negative (-) terminal of assisting battery and complete hook-up by connecting other end of negative (-) booster cable to stalled vehicle, as far away from the battery as possible. Start both vehicles and remove cables in reverse order of connection.



Maintenance free wet-cell (Ca-Ca) batteries can be stored without loosing their charge for 6 months while hybrid batteries can be stored safely for 3 months. Batteries will suffer damage if stored in a discharged state. All batteries should be kept in a cool and dry area and wet-cell batteries in particular should be stored in an upright position. Do not stack batteries directly on top of each other, unless with a separating medium such as polystyrene sheet. Top of the battery cases should be clean at all times. The batteries should follow First In First Out (FIFO) rule. This is very important about storage of batteries.

Recharging guidelines for calcium wet-cell (Ca-Ca) batteries:

  • Once in every 6 months if storage temperature is below 27°C.
  • Once in every 3 months if storage temperature is above 27°C.
  • Recharging is necessary if the open-circuit voltage drops below 12.4 volts. This method can be applied as an alternative to the first and second options above.
  • Recharging hybrid wet-cell batteries takes about half the time.

ATTENTION: During charging process, it is very important to avoid overflowing of acid and high temperatures over 52°C. If temperature does rise, either decrease the charging current or stop charging all together until battery temperature returns to a normal level. High charging temperatures will damage your battery and shorten its life.


PLEASE FOLLOW SAFETY MEASURES Prior to any testing, visually inspect the battery for:

  • Loose or broken connections
  • Cracked or broken case or cover
  • Damaged or leaking terminals

Proceed with the next step if there is no apparent damage on the battery. Testing the State of Charge: Take an open circuit voltage reading, using a reliable high quality voltmeter.

NOTE: Do not measure the charge level of a recently charged battery, in-vehicle or serviced elsewhere, since the high surface charge will be misleading. To dissipate surface charge, discharge the battery by 15x15 A. If the battery is already installed into vehicle, turn on the front headlights for 15 seconds.

The Charge Level:

  • If the voltage is around 12.4 (state of charge is 75% or higher), proceed to a load test.
  • If the voltage is below 12.4 (state of charge is below 75%), be sure to charge the battery before a load test in accordance with the charging instructions.

Voltage and density may change by various battery designs.

Load Testing: The reading of a load test is largely dependent upon the equipment used for testing. The results should be interpreted in accordance with the instructions provided by the load tester manual.
Electrical System Check: Whether you are installing a new battery or working on a defective battery, check the electrical system of the vehicle that utilizes the battery. The most damaging mistake for your vehicle would be over charging or short charging of the battery. Measure alternator output voltage: the reading should be between 13.8-14.4 volts for hybrid batteries (at full throttle); 13.8-14.8 volts for Ca-Ca batteries (in a 12 V vehicle).
NOTE: In vehicles featuring data storing computer systems, memory loss may occur with changing of the battery. To avoid cutting power to the system, install a second battery or special equipment before dismounting.

PLEASE FOLLOW SAFETY MEASURES In batteries with removable caps (non-sealed), the charge time –at temperatures 20°C to 35°C– depends upon reaching an electrolyte density of 1280 g/cm3 in all cells. Charging is complete once this value is established. After letting the battery sit for 30 minutes, adjust the electrolyte level to its maximum level, wipe the top, and then install the battery. Wet-charged batteries or customer's discharged batteries are charged according to the current levels and time periods given in the table below. Note that used batteries may not be able to reach the desired density level. In such cases, if the adjusted density remains unchanged in the last two hours, charging is considered satisfactory. Sealed batteries without removable caps (maintenance-free) are charged in accordance with voltage values.

  • Make sure the charger is turned off.
  • Measure state of charge of the battery.
  • Hook up the charger to the battery. Connect positive charger clip to positive post of battery, and negative to negative. Make sure you always look at the battery and determine the positive by the plus sign and the negative by the negative sign.
  • Select desired current and voltage in accordance with your chargers settings and instructions provided in manufacturer's manual. Start charging.
  • Once the charging is over, turn off the charger before disconnecting the clips.
  • To determine whether there is need for additional charging, measure open-circuit voltage and cell densities. You can parallel charge several batteries of same capacity, simultaneously.

SELECTING A BATTERY AND INSTALLATION The most important criteria in selecting a battery are dimensions, cold start current and capacity values.

Dry batteries require water which must be added in accordance with instructions provided above and charged if needed.

Wet-charged batteries should be recharged in accordance with instructions provided when the average daily temperatures are below 4°C and the open circuit voltage is 12.5 Volts and below. Follow the same procedure if the open circuit voltage is 12.5 Volts and below despite higher temperatures. Before disconnecting the old battery, mark all of the battery cable lugs or terminals as +/- to avoid reversed connection when installing the new battery. To install your new battery, first measure the battery voltage and its direction and confirm that all the values are correct. Then carefully inspect the battery case and the connections, clean the case and battery cable lugs. Place the battery, reconnect the cables, and tighten bolts.

Attach the positive (+) cable first and the negative ground (-) cable last. Tighten the bolts carefully; over tightening the terminal posts will severely damage the battery, especially in stud terminals.