BATTERY

DIAGNOSIS AND TESTING - BATTERY

DIAGNOSIS AND TESTING - BATTERY

A battery that will not accept a charge is inoperative, and must be replaced. Further testing is not required. A fully-charged battery must be load tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the load test, is inoperative and must be replaced.

Midtronics GR8 BATTERY TESTER

The Midtronics GR8 battery tester is designed to help diagnose the cause of an inoperative battery. (Refer to 08 - Electrical/8F - Engine Systems/Battery System/BATTERY - Standard Procedure) for instructions on the use of the Midtronics GR8 battery tester.

SPIRAL CELL BATTERY CHARGING

SPIRAL CELL BATTERY CHARGING

Special Tools: Click to display a list of tools used in this procedure

Click here to launch the form to order any tools you need.

GR8-1220KIT-CHRY - AGM Battery Tester/Charger Station Originally Shipped In Kit Number(s) GR8-1220KIT-CHRY.

Vehicles equipped with a diesel engine utilize a unique spiral cell battery. This battery has a maximum charging voltage that must not be exceeded in order to restore the battery to its full potential, failure to use the following spiral cell battery charging procedure could result in damage to the battery or personal injury.

Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when:

• Midtronics GR8-1220KIT-CHRY tester indicates battery is OK.
• Open-circuit voltage of the battery is 12.65 volts or above.
• Battery passes Load Test multiple times.

After the battery has been charged to 12.6 volts or greater, perform a load test to determine the battery cranking capacity. If the battery passes a load test, return the battery to service. If the battery fails a load test, it is faulty and must be replaced.

Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. (Refer to 08 - Electrical/8F - Engine Systems/Battery System - Cleaning) for the proper battery system cleaning procedures. (Refer to 08 - Electrical/8F - Engine Systems/Battery System - Inspection) for the proper battery system inspection procedures.

CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL CELL BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. Refer to Battery Removal and Installation for access instructions. If the reading is below ten volts, the battery charging current will be low. It could take several hours before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers.

 
2. Disconnect and isolate the battery negative cable. Connect the Midtronics GR8-1220KIT-CHRY .
   
   

   NOTE:

   Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.


 
3. Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner.
   

 

SPIRAL-PLATE BATTERY CHARGE RATE TABLE

CHARGING TIME REQUIRED

The time required to charge a battery will vary, depending upon the following factors:

• Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery.
• Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage).
• Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies eight amperes will require a shorter charging time.
• State-Of-Charge - A completely discharged battery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise.

The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity.

SPIRAL-PLATE BATTERY CHARGING TIME TABLE

CONVENTIONAL BATTERY CHARGING

CONVENTIONAL BATTERY CHARGING

Special Tools: Click to display a list of tools used in this procedure

Click here to launch the form to order any tools you need.

GR8-1220KIT-CHRY - AGM Battery Tester/Charger Station Originally Shipped In Kit Number(s) GR8-1220KIT-CHRY.

Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when:

• Midtronics GR8-1220KIT-CHRY tester indicates battery is OK. .
• Open-circuit voltage of the battery is 12.65 volts or above.
• Battery passes Load Test multiple times.

After the battery has been charged to an open-circuit voltage reading of 12.4 volts or greater, retest the battery with the Midtronics GR8-1220KIT-CHRY tester indicates battery is OK. or perform a load test to determine the battery cranking capacity. (Refer to 08 - Electrical/8F - Engine Systems/Battery System/BATTERY - Standard Procedure) for the proper battery test procedures. If the battery passes a load test, return the battery to service. If the battery fails a load test, it is faulty and must be replaced.

Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. (Refer to 08 - Electrical/8F - Engine Systems/Battery System - Cleaning) for the proper battery system cleaning procedures. (Refer to 08 - Electrical/8F - Engine Systems/Battery System - Inspection) for the proper battery system inspection procedures.

CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers.

 
2. Disconnect and isolate the battery negative cable. Connect the Midtronics GR8-1220KIT-CHRY .
   
   

   NOTE:

   Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.


 
3. Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner.
   

 

CONVENTIONAL BATTERY CHARGE RATE TABLE

CHARGING TIME REQUIRED

The time required to charge a battery will vary, depending upon the following factors:

• Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery.
• Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage).
• Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies twenty amperes or more will require a shorter charging time.
• State-Of-Charge - A completely discharged battery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise.

The Conventional Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity.

CONVENTIONAL BATTERY CHARGING TIME TABLE

IGNITION-OFF DRAW TEST

IGNITION-OFF DRAW TEST

The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the Off position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment.

A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Junction Block (JB). This will reduce battery discharging.

Excessive IOD can be caused by:

• Electrical items left on.
• Inoperative or improperly adjusted switches.
• Inoperative or shorted electronic modules and components.
• An internally shorted generator.
• Intermittent shorts in the wiring.

If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected.

1. Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to ten minutes. See the Electronic Module Ignition-Off Draw Table for more information.
   

   ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
   Module	Time Out? (If Yes, Interval And Wake-Up Input)	IOD	IOD After Time Out
   Radio	No	1 to 3 milliamperes	N/A
   Audio Power Amplifier	No	up to 1 milliampere	N/A
   Powertrain Control Module (PCM)	No	0.95 milliampere	N/A
   Cabin Compartment Node (CCN)	No	0.44 milliampere	N/A


 
2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb.

 
3. Turn off all electrical accessories.

 
4. Disconnect the battery negative cable.

   CAUTION:

   Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged.


 
5. Connect a 10 amp fused jumper wire between the negative battery cable and the negative battery post.

 
6. Turn the ignition key ON and then OFF and wait 10 minutes for all systems to enter sleep mode.
   
   

   NOTE:

   Do not break the connection between the 10 amp fused jumper wire and the battery. If the connection between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated.


 
7. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter to the battery negative cable terminal clamp and the battery negative terminal post, but not on the jumper connection.

 
8. Remove the 10 amp jumper wire without breaking the digital multi-meter connection.

 
9. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post, but not the 10 amp jumper wire.

 
10. The high-amperage IOD reading on the multi-meter should be very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the TIPM, one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete TIPM, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, diagnose and repair the Charging System as necessary. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD.

 
11. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step #10. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or an inoperative component is the cause.

 

OPEN-CIRCUIT VOLTAGE TEST

OPEN-CIRCUIT VOLTAGE TEST

A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery.

Before proceeding with this test, completely charge the battery, refer to the appropriate battery charging procedure.

1. Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the headlamps for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize.

 
2. Disconnect and isolate both battery cables, negative cable first.

 
3. Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the voltmeter), measure the open-circuit voltage.
   

 

See the Open-Circuit Voltage Table. This voltage reading will indicate the battery state-of-charge, but will not reveal its cranking capacity. If a battery has an open-circuit voltage reading of 12.4 volts or greater, it may be load tested to reveal its cranking capacity.

GR8 BATTERY TESTER / CHARGER

GR8 BATTERY TESTER / CHARGER

Always use the Midtronics GR8 Instruction Manual that was supplied with the tester as a reference. If the Instruction Manual is not available the following procedure can be used:

BATTERY TESTING

1. If testing the battery OUT-OF-VEHICLE, clean the battery terminals with a wire brush before testing, (Refer to 08 - Electrical/8F - Engine Systems/Battery System - Cleaning) . If the battery is equipped with side post terminals, install and tighten the supplied lead terminal stud adapters. Do not use steel bolts. Failure to properly install the stud adapters, or using stud adapters that are dirty or worn-out may result in false test readings.

 
2. If testing the battery IN-THE-VEHICLE, make certain all of the vehicle accessory loads are OFF, including the ignition. Connect the GR8 to directly to the battery posts.
   
   

   NOTE:

   Multiple batteries connected in parallel must have the ground cable disconnected to perform a battery test. Failure to disconnect may result in false battery test readings.


 
3. Using the ARROW key select in or out of vehicle testing and press ENTER to make a selection.

 
4. If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate battery rating for your area (see menu). The tester will then run its self programmed test of the battery and display the results. Refer to the test result table noted below.

 
5. While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character; then press ENTER to select and move to the next digit. Then press the ENTER button to view the SERVICE CODE. Pressing the CODE button a second time will return you to the test results.
   

 

Quick Reference Guide

Inspect the battery for damages and check the electrolyte level. Always use the necessary safety precautions when working with batteries to prevent severe injury or death. Follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations, which include the following precautions:

Main Menu

The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons lead directly to the function they represent, while others are menu icons that lead to two or more options.

Automatically tests, charges, and provides battery decision using the information you select in a series of screens. Start here to generate warranty codes.

Tests the starting and charging systems.

Maintains battery voltage at 13.5 volts to provide uninterrupted reprogramming of ECUs and retain vehicle system settings.

Includes a utility to view and print a test counter, a data transfer utility, the software version and date, the GR8 serial number for the control module, and current wireless channel.

The Setup Menu lets you customize options in the GR8 to suit your needs.

Provides a list of topics and definitions. Also includes Midtronics Customer Service phone numbers.

Charge/Test Menu

Automatically tests and charges battery, starting, and charging system. Generates a warranty code for Replace and Bad Cell decisions.

Pre Delivery Inspection (PDI): For testing delivered vehicles and lot maintenance. Uses the same inputs as a diagnostic charge.

Dual Battery Charge mode allows the charger to be used with dual battery systems.

Makes high output current available to boost charge an in-vehicle battery and assist in starting the engine.

Provides a timed charge that ranges from 5 to 120 minutes or a continuous charge that ends when you press the STOP key.

In this mode the charger can provide a trickle charge for long term, low amp battery charging.

Generates 15-digit warranty codes for physically defective batteries or customer good will.

1. Control module: Backlit graphical display and keypad for data entry.

 
2. ON/OFF switch: ON/OFF switch Turns power on and off to the GR8.

 
3. STATUS light: Lights in conjunction with beeping alarm to indicate transitions and warnings.

 
4. Data card slot: For future upgrades via a data card. The slot contains a plastic filler card for protection.
   

 

Replace Battery Decisions

Battery Decisions

1. Battery Decisions

 
2. Select Rating

 
3. Measured capacity

 
4. Measured voltage

 
5. Good Range
   
   

   NOTE:

   The warranty code screen will only be displayed for REPLACE BATTERY and BAD CELL-REPLACE decisions.


 
6. Enter this number into wiTech

 
7. Replace range

 
8. Replaced AMP Hours

 
9. Charging Time
   

 

Test Results-Charging System

A REPLACE BATTERY or BAD CELL-REPLACE decision gives you the option of generating a warranty code. For Chrysler vehicles model year 2011 or later, enter that warranty code into your wiTECH in the Midtronics warranty code validation routine.

1. Loads-off current at rev if amp clamp is used

 
2. Loads-off DC voltage at rev

 
3. Decision

 
4. Loads-on DC voltage at rev

 
5. Loads-on current at rev if amp clamp is used

 
6. Bar graph of DC voltage within normal range (loads on and off)

 
7. Graph of diode waveform

 
8. Peak-to-peak AC voltage

 
9. Normal DC voltage range
   

 

Test Results-Starter System

1. Average cranking voltage

 
2. Average cranking current if amp clamp is used

 
3. Cranking time in seconds

 
4. Y axis = System performance: cranking voltage
   

 

REMOVAL

REMOVAL

1. Loosen the pinch clamp bolt and disconnect and isolate the battery negative cable (8).

 
2. Loosen the pinch clamp bolt and disconnect the battery positive cable (4).
   
   

 
3. On gasoline engine equipped vehicles, loosen bolt (2) and remove the retainer (1) that holds the battery (3) down to the tray (4).
   
   

 
4. On diesel engine equipped vehicles, loosen the bolts (2 and 3) and remove the retaining bracket that holds the battery (4) down to the tray (5).

 
5. Remove the battery from the vehicle.

 
6. Remove thermal guard (if equipped) from battery.
   

 

INSTALLATION

INSTALLATION

1. Install battery into the vehicle making sure that the thermal guard (if equipped) is present and battery is properly positioned on battery tray.
   On diesel engine equipped vehicles, position the retaining bracket onto the battery (4) and install the bracket bolts (2 and 3). Tighten the bolts to 7 N·m (62 in. lbs.)
   
   

 
2. On gasoline engine equipped vehicles, install the battery hold down retainer (1) and bolt (2) making sure that it is properly positioned on battery (3). Tighten the hold down bolt to 7 N·m (62 in. lbs.)
   
   
   

   WARNING:

   The battery negative and positive cable polarity are different from the gasoline engine equipped vehicles to the diesel engine equipped vehicles. Please note the location of the positive and negative cables prior to service of the battery or related components.

   
   
   

   NOTE:

   Left hand drive gasoline engine shown, left hand drive diesel similar. Right hand drive gasoline and diesel similar with the battery and related components packaged on the left side of the engine compartment.


 
3. Connect the battery positive cable (4) and tighten the pinch clamp nut to 5 N·m (45 in. lbs.)

 
4. Connect the battery negative cable (8) and tighten the pinch clamp nut to 5 N·m (45 in. lbs.)

 
5. Verify proper vehicle operation.