Battery: Testing and Inspection
BATTERY CHECK
BATTERY VISUAL INSPECTION (1)
The battery contains a visual test indicator which gives green sign when an adequate charge level exists, and dark sign when charging is required.
BATTERY VISUAL INSPECTION (2)
Make sure the ignition switch is in "LOCK" (OFF) position and all battery feed accessories are OFF.
1. Disconnect the negative cable from battery before disconnecting the positive cable.
WARNING: Care should be taken in the event battery case is cracked or leaking to protect hands from the electrolyte. A suitable pair of rubber gloves (not the household type) should be worn when removing battery by hand.
2. Remove the battery from the vehicle.
3. Inspect the battery carrier for damage caused by loss of acid from battery. If acid damage is present, it will be necessary to clean area with a solution of clean warm water and baking soda. Scrub area with a stiff bristle brush and wipe off with a shop towel moistened with ammonia or baking soda in water.
4. Clean the top surface of the battery with same solutions as described in step 3.
5. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
6. Clean the battery post with a suitable battery post cleaning tool.
7. Clean the inside surfaces of the terminal clamps with a suitable battery terminal cleaning tool. Replace damaged or frayed cables and broken terminal clamps.
6. Install the battery in the vehicle.
9. Connect positive and negative cables to the battery in the order of mention.
10. Tighten the clamp nut securely.
BATTERY CHARGING
WARNING: When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke near batteries on charge or which have recently been charged. Do not break live circuits at the terminals of the batteries on charge. A spark will occur where the live circuit is broken.
Keep all open flames away from the battery.
Battery electrolyte temperature may temporarily be allowed to rise to 55 °C (131 °F). Increase of electrolyte temperature above 55 °C (131 °F) is harmful to the battery, causing deformation of battery cell, decrease in life of battery, etc.
CHARGE RATE
If the test indicator is white, the battery should be charged as outlined below.
When the dot appears or when maximum charge shown below is reached, charging should be stopped.
BATTERY TESTING PROCEDURE
STEP 1. Check the battery cables.
1. Remove the negative cable, then the positive cable.
2. Check for dirty or corroded connections.
If the battery cables are dirty or have corroded connections, clean the battery cables. Then go to Step 2.
If the battery cables are normal, go to Step 2.
STEP 2. Check the battery post.
Check for loose battery post.
If the battery post is faulty, replace the battery. Then go to Step 4.
If the battery post is normal, go to Step 3.
STEP 3. Check the battery case and cover.
1. Remove the hold-downs and shields.
2. Check for broken/cracked case or cover.
If the battery case or cover is faulty, replace the battery. Then go to Step 4.
If the battery case or cover is normal, go to Step 4.
STEP 4. Check the open circuit voltage.
1. Turn headlights on for 15 seconds.
2. Turn headlights off for two minutes to allow battery positive voltage to stabilize.
3. Disconnect the battery cables.
4. Read open circuit voltage.
- Open circuit voltage should be 12.4 volts or more.
If less than 12.4 volts, go to Step 5.
If 12.4 volts or more, go to Step 6.
STEP 5. Charge battery.
Charge the battery at 5 amps for 15 hours. Then re-test, go to Step 4.
STEP 6. Check the load test.
1. Connect a load tester to the battery.
2. Load the battery at the recommended discharge rate (See LOAD TEST RATE CHART) for 15 seconds.
3. Read voltage after 15 seconds, then remove load.
4. Compare the measured value with the minimum voltage. (See LOAD TEST CHART.)
- Voltage should be higher than minimum voltage.
If less than minimum voltage, replace the battery. Then go to Step 4.
If higher than minimum voltage, battery is normal.
Load Test Chart:
Load Test Rate Chart:
