BATTERY DIAGNOSTIC TEST (1)
1. CHECKING FLOW

2. CHECKING SHEET
Inspection Items &
contents
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Judgment criteria
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Responsibility
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Remarks
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User
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Manufacturer
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1. Acid Leakage * Type of acid leakage
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Leakage on the fusion part for joining
the case and cover. |
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Leakage on the terminal
part |
*
Conduct a visual inspection for breakage, deformation, or
cracks.
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1. Damage in
the case or cover due to outside impact.
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2. Acid
leakage on the molding part of the case or cover. (weld line or gate hole)
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3. Damage on
the terminal or cracks in the cover.
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4. Acid
leakage due to the tipped battery or slant storage.
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5. Acid
leakage due to poor welding of the cover. (with no damage)
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2. Outside damage and
breakage
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1. Outside
damage due to causes without damage due to
mistreatment.
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2. Outside
damage due to mistreatment.
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3. Damage due
to a spark between terminals.
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4. Damage and
breakage due to heat.
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3. Measure the voltage for the
battery ; Wait at least one day before
measuring in case of recharging.
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1.
12.0V
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Refer to load
test
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2. 11.0V<
battery voltage<12.0V due to over-discharge.
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Refer to load
test
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3. Below 11.0V
due to charge condition failure.
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Refer to load
test
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4. Below 11.0V
due to discharged for a long period.
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Refer to load
test
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5. Below 11.0V
due to internal short circuit.
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Refer to load
test
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4. Load test ; For 15 seconds with half of the CCA
value. The voltage on the dischaarging
stage should be above 9.6V (81±9°F)
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Conduct the test with a battery
tester.
(Refer to the tester
manual) | |
1. Load test
result: below 9.5V
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2. Load test
result: above 9.6V
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3. LOAD TEST
1. |
Perform the following steps to complete the
load test procedure for maintenance free
batteries. |
2. |
Connect the load tester clamps to the
terminals and proceed with the test as follow :
A. |
If the battery has been on charge,
remove the surface charge by connecting a 300 ampere load for
15 seconds. |
B. |
Connect the voltmeter and apply the
specified load. |
C. |
Read the voltage after the load has been
applied for 15 seconds. |
E. |
Compare the voltage reading with the
minimum and replace the battery if battery test voltage is
below that shown in the voltage
table. |
Voltage
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Temperature
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9.6
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20°C
(70°F) and above
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9.5
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16 °C
(60 °F)
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9.4
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10 °C
(50 °F)
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9.3
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4 °C
(40 °F)
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9.1
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-1 °C
(30 °F)
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8.9
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-7 °C
(20 °F)
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8.7
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-12 °C
(10 °F)
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8.5
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-18 °C
(0 °F)
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If the voltage is higher than
shown in the table, the battery is
good. |
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If the voltage is lower than shown
in the table, replace the
battery. | | |
BATTERY DIAGNOSTIC TEST (2)
1. |
Make sure the ignition switch and all
accessories are in the OFF
position. |
2. |
Disconnect the battery cables (negative
first). |
3. |
Remove the battery from the
vehicle.
Care should be taken in the event the
battery case is cracked or leaking, to protect your skin from
the electrolyte. Heavy rubber gloves (not the household type)
should be worn when removing the
battery. |

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4. |
Inspect the battery carrier for damage caused
by the loss of electrolyte. If acid damage is present, it will be
necessary to clean the area with a solution of clean warm water and
baking soda. Scrub the area with a stiff brush and wipe off with a
cloth moistened with baking soda and
water. |
5. |
Clean the top of the battery with the same
solution as described in Step(4). |
6. |
Inspect the battery case and cover for cracks.
If cracks are present, the battery must be
replaced. |
7. |
Clean the battery posts with a suitable
battery post cleaming tool. |
8. |
Clean the inside surface of the terminal
clamps with a suitable battery cleaning tool. Replace damaged cables
and broken terminal clamps. |
9. |
Install the battery in the
vehicle. |
10. |
Connect the cable terminals to the battery
post, making sure the tops of the terminals are flush with the tops
of the posts. |
11. |
Tighten the terminal nuts
securely. |
12. |
Coat all connections with light mineral grease
after tightening.
When batteries are being charged, an
explosive gas forms beneath the cover of each cell. Do not
smoke near batteries being charged or which have recently been
charged. Do not break live circuits at the terminals of
batteries being charged. A spark will occur when the circuit
is broken. Keep open flames away from the
battery. |

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