The battery information contained in this publication is intended for a professional technicians.

Please do no attempt any of the maintenance/repair

procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.


Battery Charging
NOTE
Before charging a battery, read the Battery Safety Information under the Resources dropdown.

Batteries in good condition, but somewhat discharged, may not provide enough energy to crank the engine.
These batteries may need to be charged. Fully charged batteries are a must to insure accurate results when you
are troubleshooting problems in the starting system or the charging system. You need to know how to properly
charge batteries to conduct such tests. Fully charged batteries are also required to meet fleet service needs. In
such cases, group charging with either a series a parallel charger saves time and insures a ready supply of
good batteries.
Generally, a fully charged battery will have an open circuit voltage of at least 12.6 volts, while a discharged
battery will have an open circuit voltage of 12.0 volts or less. More specifically, discharged maintenance-free
batteries will show a dark eye (if so equipped), while discharged filler cap batteries will have average
hydrometer readings below 1.230.
To effectively diagnose and repair problems on electrical systems, you will need to know about:
Charging maintenance-free batteries
Charging filler cap batteries
Charging AGM batteries
Group charging with series chargers
Group charging with parallel chargers.

Factors Affecting Charging
Whether you are charging maintenance-free batteries or filler cap batteries, the charging rate will be affected by:
Battery Size or Capacity - A discharged 110 minute reserve capacity rated battery needs more charging
time than a discharged 80 minute reserve capacity rated battery.
Electrolyte Temperature - A cold battery takes longer to charge than a warm battery; about two hours longer
at 0F than at 80F. The initial charging current will be low, then increase as the battery warms. Never
attempt to charge a frozen battery.
State-of-Charge - A completely discharged battery needs twice the amp hours as a half-charged battery to
become fully charged. The initial charging current will be low; the electrolyte is mostly water. The current will
increase as the electrolyte acid content increases.
Battery Age and Condition - An older battery in severe service will need up to 50% more amp hours of
charging than a newer battery.
Charger Capacity - A charger that can supply only 5 amps will take much longer than one that supplies 30
amps.

Charging ACDelco Filler Cap Batteries
A dry-charge battery has charged plates but contains no electrolyte. These batteries can be stored for long periods but
must be filled and charged prior to service.
A wet-charge battery has charged plates and is filled with electrolyte. These batteries lose their charge in storage and
must be periodically recharged.



The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.


NOTE
Leave dry-charge batteries in their original shipping cartons; store at 60F or higher. Periodic recharging is needed on
wet-charge batteries, especially when storage is above 60F. Store these in cool areas.
The state of charge on filler cap batteries must be checked by measuring the strength of the electrolyte. Specific
gravity (exact weight) of the electrolyte provides a measure of its strength. Pure water is lighter than the correct
mixture of acid and water. A hydrometer is used to measure the specific gravity of the electrolyte in each battery cell.
These readings, adjusted for the temperature of the electrolyte, are used to determine the batterys state of charge.
CAUTION
All lead-acid batteries generate hydrogen gas, which is highly explosive. If ignited by a flame or spark, the
gas may explode violently. When working near batteries, always wear safety glasses, remove watches or
jewelry, and avoid causing sparks with tools. If splashed with acid, immediately flush area with water and
seek medical attention.

Charging Procedure
Service bulletins are available for specific battery charging procedures. Fast charging is only recommended if
using a smart charger, which provides constant voltage/variable current. Other fast charging methods may
shorten battery life. General guidelines for charging ACDelco filler cap batteries are given here.
NOTE
During charging, leave flame arrester vent caps in place. Remove sealed caps and place a cloth over the vent
holes to allow gassing.
1. When charging or testing sealed-terminal (nonpost type) batteries, use terminal adapters (ST-1201)
when the batteries are removed from the vehicle. Connect charger clamps to battery studs/nuts when
the batteries are in vehicle.
2. The battery terminal voltage does not exceed 15 volts, the electrolyte doesnt spew from the vent holes,
or the battery does not feel excessively hot (>125F). The charging current may need to be reduced or
temporarily stopped to prevent damage to the battery.
3. The battery is fully charged when, after two hours of charging at a low rate, all cells are gassing freely
and no change in the electrolytes specific gravity is noted. Specific gravity should be at least 1.230.
Batteries may function, even with specific gravity below 1.230
Emergency boost charging must be followed by full charging
4. Battery charging requires a charge current (in amperes) for a period of time (in hours).
5. The time required for a proper charge will vary according to:
Battery size or capacity
Electrolyte temperature
State of charge
Battery age or condition
Charger capacity.
NOTE
After charging has been completed, add water to adjust the electrolyte level in each cell to the bottom of the split ring.




The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.


Charging ACDelco Maintenance-Free Batteries
The Adapter Kit (ST-1201) is available from ACDelco. It is recommended that this adapter kit, or equivalent, be used
in charging sealed-terminal batteries when they are out of the vehicle.
When the sealed-terminal battery is in the vehicle, connect the chargers leads to the studs/nuts at the batterys
terminals. Post-type batteries need no adapters.
The following basic rules apply to most ACDelco battery charging situations:
1. Charge rates between 3 and 50 amperes are generally satisfactory for any Maintenance-Free Battery as long
as spewing of electrolyte does not occur or the battery does not feel excessively hot (>125F [>52C]). If
spewing occurs or temperature exceeds 125F, the charging rate must be temporarily halted to permit
cooling.
Battery temperature can be estimated by touching or feeling the battery case.
If equipped with a hydrometer, the battery is sufficiently charged when the green dot in the built-in hydrometer
is visible. No further charging is required. Shake or tilt the battery at hourly intervals during charging to mix
the electrolyte and see if the green dot appears.
If the battery is not equipped with a hydrometer, use an automatic taper-rate (decreasing current) charger.
Charge the battery in a well-ventilated area. Wear protective eyewear and clothing, and keep sparks and
flames away from charging batteries. Charge the battery until the charger operation indicates the battery is
fully charged (refer to charger manufacturers instructions).
The time required for a charge will vary because:
Size of Battery - A completely discharged large heavy-duty battery requires more than twice the recharging as a
completely discharged small passenger car battery.
Temperature - A longer time will be needed to charge any battery at 0F than at 80F. When a fast charger is
connected to a cold battery, the current accepted by the battery will be very low at first, then in time, the battery will
accept a higher rate as the battery warms.
State-of-Charge - A completely discharged battery requires more than twice as much charge as an onehalf-charged
battery. Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery, the
current accepted is very low at first. Later, as the charging current causes the electrolyte acid content to increase, the
charging current will likewise increase.
Charger Capacity - A charger which can supply only 5 amperes will require a much longer period of charging than a
charger that can supply 30 amperes or more.
Water never needs to be added to maintenance-free batteries. The battery cover is sealed and has no filler caps.
Small vent holes allow any gases produced to escape. Special battery plates minimize gassing at normal charging
currents and also limit the possibly of overcharge damage.
NOTE
Do not tilt a maintenance-free battery beyond a 45 angle in any direction. This would allow electrolyte to leak from the
vent holes.
CAUTION
All lead acid batteries generate hydrogen gas which is highly explosive. If ignited by a flame or spark, the gas may
explode violently. When working near batteries, always wear safety glasses, remove watches or jewelry, and avoid
causing sparks with tools. If splashed with acid, immediately flush skin or eyes with water and seek medical attention.




The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.


Charging AGM Batteries
The ACDelco AGM Battery may be charged by most commercially available battery chargers if the charging process
is properly monitored. The guideline is to charge the battery as fast as possible, but to avoid causing its built-in valve
to open and allow too much of the internal gases to escape.
Good Practices
Use a modern, taper-rate charger to charge the AGM Battery. These chargers are sometimes referred to as
automatic, and feature a decreasing current as the battery approaches full charge. When the charger operation
indicates that the battery is fully charged (refer to charger manufacturers instructions), remove the battery from
charge. Laboratory tests have shown that AGM batteries respond very well to such chargers.
To charge the battery:
1. Use an automatic taper-rate (decreasing current) charger. Charge the battery in a well-ventilated area. Wear
protective eyewear and clothing, and keep sparks and flames away from charging batteries.
2. When charging the battery in the vehicle, be sure the ignition switch is turned to OFF. This will help prevent
accidental damage to vehicle components and avoid current drains that would prevent efficient battery
charging.
3. Be sure a good connection is available to the battery terminals. If the battery is being charged in the vehicle
with the battery cables still attached, clean away any dirt or corrosion from the connecting surfaces.
When the battery is being charged out of the vehicle or without the battery cables attached, side terminal
batteries must have suitable adapters installed in the terminals, such as ACDelco catalog no. ST-1201. Wire
brush the terminal face and the contact area of the adapter before installing the adapter. Never use bolts or
combinations of bolts, nuts, and washers as adapters since they may introduce resistances into the charging
circuit and cause slower or incomplete recharge. Also, use of other commercially available side terminal
adapters should be limited to those adapters that directly contact the current-carrying face of the terminal.

4. Be sure the charger is turned OFF or disconnected from the power source.
5. Connect the positive charger cable to the battery positive terminal, then the negative charger cable to the
negative battery terminal.
6. Turn the charger ON, or connect it to the power source.
7. Charge the battery until the charger operation indicates the battery is fully charged (refer to charger
manufacturers instructions).
8. Turn OFF the charger or disconnect its power source.
9. Disconnect the charger cable from the negative battery terminal, and then disconnect the charger cable form
the positive battery terminal.
Using Other Charging Methods
Some older charging equipment may not offer the automatic, self-limiting features available on more recent chargers.
However, AGM batteries can be successfully charged with such equipment by proper monitoring.
If a constant-current charger must be used, either directly or in a series hookup, it is recommended that the charge
rate be limited to 10 amperes or less.
Do not allow the battery to be constantly charged at 3 amperes for more than 10 hours, or at 10 amperes for
more than 5 hours. When these time limits have been reached, stop the charge and allow the battery to rest
overnight. Resume the charge the next day.
The charging voltage will increase as the battery nears full charge. Check the charging voltage across the
individual batterys terminals every 30 minutes, and remove the battery from charge when the voltage
reaches 15 volts. When the charging voltage across a battery reaches 15 volts at a constant current rate of 3
to 10 amperes, the battery state of charge will be at 90 to 95%.


The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.


If parallel charging must be used, monitor the charging voltage.
When the voltage reaches 15 volts, maintain the voltage at 15 volts and monitor the current flow into each
battery every 30 minutes.
The current flow will decrease as the battery nears full charge. When the current into an individual battery
falls below 10 amperes at 15 volts, the battery will be at a 90% state of charge or more and charging of that
battery should be stopped.
The features of automatic, self-adjusting chargers may result in conditions which at times appear to exceed the above
recommendations. Following these guidelines when using older equipment will prevent situations that could
inadvertently shorten the battery life.

Charging Voyager Deep Cycle Marine/RV Battery
The ACDelco Voyager Marine/RV Battery is a deep cycle battery that will give hours of electrical power in recreational
vehicle and boating applications. The battery is an energy storage reservoir. When energy is removed from the battery
it must be put back by recharging. The amount of energy to be put back depends on how much was taken out. The
time it will take depends on the ampere output of the charger used.
The typical ACDelco Voyager Battery may have a built-in state-of-charge indicator to show how much energy is left in
the battery. A green or red colored ball may be visible in the indicator, or no ball may be visible causing the indicator
to appear dark. The indicator is also used to determine how long the battery should be recharged as follows.
Important points for good battery performance and life:

Figure 4-22, Battery Recharge Table
1. Recharge battery after each use.
2. Use a taper-type charger. For best results, a 10-15 amp taper-type charger is recommended to recharge
ACDelco Voyager models. Taper chargers help avoid overcharge by reducing the charge rate as the battery
nears full charge. Follow instructions provided with the charger.
3. Determine the charging time that will be required. Check the built-in indicator and charge the battery for at
least the number of hours shown in Figure 4-19. If the green ball is not visible in the indicator after charging,
tap lightly on top to dislodge trapped air bubbles that might keep the ball from floating into view. If the green
ball is still not visible, continue charging until it appears.
NOTE
A more definite charging time can be set if an accurate voltmeter is available for reading open circuit voltage.
4. Do not leave the battery connected to a battery charger after the battery is fully charged.
5. Batteries charge more efficiently at 60 to 80F.
6. Keep battery in a cool place when storing for long periods (make sure battery is fully chargeda discharged
batterys electrolyte can freeze).




The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.


Multi-Battery Charging
Two different types of charges can be used for group charging batteries:
Current-Limiting (constant current or series chargers)
Voltage-Limiting (constant voltage or parallel chargers).
With series chargers, the batteries are connected so that each battery receives the same amount of charging current.
With parallel chargers, the batteries are connected so that the charging current is divided and each battery receives
only the charging current it can accept at the chargers voltage. As such, the charging procedures are different.
No matter which type of charger is used, the procedures outlined here must be closely followed to prevent under-
charging or overcharging and battery damage on the charging rack. Be aware that the batteries may vary in age,
capacity or size, state of charge, and type.
NOTE
The recommended group charging procedures are for batteries with electrolyte and plates at normal room
temperatures (55F to 85F). Extremely cold batteries will accept very little charging current and must be warmed
before charging.
Group Charging with Series Chargers
Series charging is not recommended. If series charging is used, monitor batteries hourly for spewing, gassing, and
case temperature above 125F or charging voltage above 16 volts. If this occurs, remove batteries and load test. A
four-step process can be followed, using a series or current-limiting charger. Differences in group charging
maintenance-free batteries and filler cap batteries are noted:
1. Visually inspect all batteries for cracked covers or cases. Replace damaged batteries.
Maintenance-Free Batteries: If so equipped, check the built-in hydrometer. If the color is green, the
battery should not be charged and can be load tested. If the eye is dark, proceed with charging. If the eye
is clear or yellow, the battery must be replaced.
If the batteries are not equipped with a hydrometer, use an automatic taper-rate (decreasing current)
charger. Charge the batteries in a well-ventilated area. Wear protective eyewear and clothing, and keep
sparks and flames away from charging batteries. Charge the batteries until the charger operation
indicates the batteries are fully charged (refer to charger manufacturers instructions).
Filler Cap Batteries: Check each cell with a hydrometer. If the reading is 1.230 or more, the battery
should not be charged and can be load tested. If the reading is below 1.230, continue with the charging
procedure. If the electrolyte level is low, add just enough water for taking readings and then proceed with
charging, if needed. After charging, fill each cell to the split ring.
2. Connect batteries to charger, as shown in Figure 4-20. Do not exceed the chargers voltage capabilities by
connecting too many batteries. Make sure all connections are clean and tight. Set the charging rate within a 5
to 10-amp range and maintain this charging rate throughout the procedure.
3. After two or three hours of charging, check the batteries:

Maintenance-Free Batteries: If so equipped, regularly check the hydrometer for a green dot. Shake
or tilt batteries at hourly intervals to see if green dot stays visible. Also, check the battery terminal
voltage with a voltmeter. During charging (both hydrometer and non-hydrometer), if the voltage is 16
volts (or more), remove the battery for load testing. After removal, adjust the charger control to
maintain the previously set charging rate.
Filler Cap Batteries: Take hydrometer readings at hourly intervals. Correct readings to 80F (27C).
Remove any battery from being charged when there is no increase in specific gravity after three
successive hourly readings. Any battery that gets too hot (>125F), or gases excessively, should be
removed for load testing. After removing any battery, adjust the charger control to maintain the
previously set charging rate.


The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.



4. After charging, all batteries should be load tested; that procedure is described earlier in this section and
also in Service Bulletin 1B-115 (for filler cap batteries) and in Service Bulletin 1B-116 (for maintenance-
free batteries). Remove surface charge, if necessary; that procedure is also described earlier in this
chapter.

Figure 4-23, Series Charging
Group Charging with Parallel Chargers
A four-step process can be followed, using a parallel or voltage-limiting charger. Differences in charging maintenance-
free batteries and filler cap batteries are noted:
1. Visually inspect all batteries for cracked covers or cases. Replace damaged batteries.
Maintenance-Free Batteries: Check the built-in hydrometer. If the color is green, the battery should not be
charged and can be load tested. If the eye is dark, proceed with charging. If the eye is clear or yellow, the
battery must be replaced.
If the batteries are not equipped with a hydrometer, use an automatic taper-rate (decreasing current)
charger. Charge the batteries in a well-ventilated area. Wear protective eyewear and clothing, and keep
sparks and flames away from charging batteries. Charge the batteries until the charger operation
indicates the batteries are fully charged (refer to charger manufacturers instructions).



The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.


Filler Cap Batteries: Check each cell with a hydrometer. If the reading is 1.230 or more, the battery
should not be charged and can be load tested. If the reading is below 1.230, continue with the charging
procedure. If the electrolyte level is low, add just enough water for taking readings and then proceed with
charging, if needed. After charging, fill each cell to the split ring.
2. Connect batteries and voltmeter to charger, as shown in Figure 4-21. Make sure all connections are clean
and tight. Set the charging voltage to 15 volts or less for filler cap and AGM batteries and 16 volts or less for
maintenance-free batteries. The charger may not reach this initially, but as the batteries become charged and
accept less current, the voltage will rise. The ammeter on the charger will indicate the total current flow to the
batteries. But the current divides, so the ammeter reading is not a measure of each batterys charging
current. Do not exceed the chargers voltage capabilities by connecting too many batteries, always follow the
chargers instructions.
3. After two or three hours of charging, check the batteries:
Maintenance-Free Batteries: If so equipped, regularly check the eye for a green dot. Stop charging
when the eye stays green. Any battery that gets too hot (>125F), or gases excessively, should be
removed from the charger and tested. Continue charging the remaining batteries, since they received
little charging current. As batteries are removed, make sure you adjust the charging voltage to 16
volts or less on the remaining batteries (both hydrometer and non-hydrometer).
Filler Cap Batteries: Take hydrometer readings at hourly intervals. Correct readings to 80F (27C).
Remove any battery from being charged when there is no increase in specific gravity after three
successive hourly readings. Any battery that gets too hot (>125F), or gases excessively, should be
removed for load testing. Most of the charging current was likely going to that battery, with the
remaining batteries receiving little, so continue charging the other batteries.
4. After charging, all batteries should be load tested; that procedure is described earlier in this section and also
in Service Bulletin 1B-115 (for filler cap batteries) and in Service Bulletin 1B-116 (for maintenance-free
batteries). Remove surface charge, if necessary; that procedure is also described earlier in this chapter.



The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.



Alternate Method for Determining Charge Time
If an accurate voltmeter is available, the required time for charging can be determined more closely. Depending on
actual battery state-of-charge, this may be more or less than the minimum time determined from the built-in indicator.
IMPORTANT
Do not measure open circuit voltage right after recharging the battery. Surface charge may cause a false higher voltage
reading. Measure only after battery has been standing with no electrical loads for 24 hours or more.
Determine the hours of charging that will be required. Use an accurate voltmeter to measure the open circuit voltage,
then use Figure 4-22 to determine how long to charge the battery.
Example: If the open circuit voltage is 12.1 volts, find 12.1 volts on the left side of the chart. If a taper charger rated at
10 amps is used, go horizontally across the chart until the line for the 10 amp charger is reached (follow dotted line).
From this point, read the required hours of charge directly below on the bottom line (17 hours).
The battery will be fully charged at the end of the time shown in Figure 4-22. The green ball should be visible in the
built-in indicator. If not, tap the indicator lightly on top to dislodge any trapped air bubbles that might keep the ball from
floating into view.


The battery information contained in this publication is intended for a professional technicians. Please do no attempt any of the maintenance/repair
procedures if you are not licensed or appropriately trained. Do not distribute or share the digital or printed material, including pdf versions of the
content. Also, do not provide a link to this material to another website or email address. This material may be protected under copyright and
trademark laws.



Figure 4-25, Hours of Charge
Charging Voltage and Charging Rates
Similarly, Figure 3-7 shows the charging voltages and charging rates for warm and cold batteries. The curves shown
assume generator output is sufficient to provide the voltage and current required.

For a fully charged battery, the charging rate should be reasonably low to protect the battery from overcharging and
overheating. This low charging rate does indeed occur at the regulator limit when the battery is cold (see Figure 3-7).
However, when the battery is hot, the charging rate is significantly higher. This occurs because battery resistance
decreases at high temperatures which increases charging current flow.
While the high rate of charge on a fully charged battery is generally undesirable, no damage occurs as long as the
condition is not present for long periods of time. Applying a high rate of charge to a partially charged battery is
desirable because the battery should be recharged to full capacity in the shortest amount of time.
Because temperature does have such a dramatic effect on battery operation, some charging systems designed for
extreme hot or cold are equipped with regulators that automatically adjust voltage settings with the temperature. The
regulator allows a higher voltage setting during cold weather and a lower voltage setting during hot weather.

Figure 3-7, Charging Rates for Hot and Cold Batteries