Know-How expensive battery boosting
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FEW within our industry would find difficulty in completing that old saying, "The best-laid plans . . ." This does not hint at pessimism, just indicates that in transport there is usually a new surprise, hazard or unscheduled expense just around the corner. Therefore to find that one of your carefully planned "stitch in time" schemes has backfired rather expensively can be a good deal more annoying than surprising.
In a large industrial site some 13 miles from home base, 11 medium and heavy vehicles worked entirely within the works boundary, and quite naturally all but one were untaxed, having no duties on public roads. In order that they could be serviced, trade plates were needed to bring the untaxed ones to the garage.
When this became something of a problem due to drivers hours of duty, it was decided to take light maintenance to the vehicles. This was achieved quite simply via compressor and air equipment, greaser, drill, impact wrench, etc., and to improve availability, one skilled and one semi-skilled mechanic worked a late shift from 2 until 10 p.m.
This worked quite well until the colder weather began to present starting problems. It was discovered that the limited nature of operations within the works failed to keep the batteries charged. It then became necessary to find a mains supply and introduce a battery booster to guarantee a quick morning start. Again this scheme paid off, and starting problems vanished as each battery received several solid hours' charge each week.
However, new problems came along in the form of regulator and dynamo trouble and as this expense mounted, it became imperative that the cause be found. Thoughts turned to the booster; this unit was tested for constant and correct charge rate and cleared of suspicion.
Only by chance was it noted that when the mechanic coupled the charger to the batteries, he also reached into the cab and turned on the charging switch with its warning light in the belief that this circuit must be closed in order to charge the batteries. The result of this was that power was flowing to the regulator causing overheating and damage, and on at least two occasions bridging the cut-out points and running the solder from the commutator.
Although this damage feature does not apply to all control units, it should be made clear to all mechanics that before switching on a battery booster they should ensure that all switches, including the ignition or charging switch, master or auxilliary switches, are in the off position. And if in any doubt at all, they should disconnect the battery terminals before boosting.