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Testing Procedures

Testing Procedures

Caution:
Batteries produce explosive gases, contain corrosive acid and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery, always shield your eyes and avoid leaning over the battery whenever possible. Do not expose the battery to open flames or sparks. Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly, any contacted areas with water and get medical help.

Proper Testing requires that the following test procedures be followed;

Important:
Complete the "Electrical System Diagnostic Work Sheet" as you perform the test steps outlined below. IF YOU WISH TO PRINT THE ELECTRICAL SYSTEM DIAGNOSTIC WORK SHEET ONLY, YOU MAY REFER TO CORPORATE BULLETIN NUMBER 02-06-03-011.

Battery Inspection and Test Portion

1. Inspect the battery for evidence of physical damage or leakage. If damage or leakage is found, replace the battery. If no damage or leakage is found, proceed to Step 2.

Leaking batteries are to be claimed using failure code "6J" and do not require a Midtronics test code.

^ If the battery has leaked, the battery tray and surrounding area should be neutralized with a baking soda and water solution. (This is a Straight time: Add operation requiring Service Management authorization).

^ If the battery has leaked and soaked the battery insulator blanket, a new battery insulator blanket must be installed on the new battery.

2. Is the hydrometer eye, if equipped, clear (low electrolyte level)? If clear, tap the hydrometer lightly with the handle of a small screwdriver. Did the color change? If no, replace the battery. If yes, continue with Step 3.

Important:
The pad/post of the battery must make solid and complete contact with the terminal/connector pad of the battery cable. This interface must be clean and corrosion free. The positive terminal is always sealed to the case by the vinyl covering on the battery cable end. On many vehicles, the negative terminal is also sealed. The attachment bolt is to hold the battery cable end terminal firmly on the battery. It is not designed as the carrier of the current.

3. Attempt to rotate both battery cables. Properly torqued battery cables will have a break-away torque requirement of 15 N.m (10 lb-ft). If the bolt is tight and the battery cable end does not rotate, continue with the next step. If the bolt is tight and the battery cable end rotates, it may be due to one of the following conditions:

^ The battery cable end may be damaged. Inspect and replace the damaged component as required.

^ The attaching bolt is cross threaded. Refer to Corporate Bulletin 02-06-04-015 for the proper repair procedure.

^ The attaching bolt may be too long. Replace the battery cable bolt, if necessary.

^ Inspect for the presence of foreign material lodged in the battery bolt hole. Repair as necessary.

4. Connect the Midtronics Digital Battery Analyzer, (tester), J 42000 to the battery terminals. Rock the J 42000 Battery Tester clips back and forth on the cable attaching bolts to cut through any coating or oxidation that may be present. For further information regarding the tester refer to: Testing the Battery with the Midtronics Micro 410 Tester, J 42000, found later in this bulletin.

Important:
^ For AGM batteries, you must enter 100 CCA more than the CCA value displayed on the battery label, when using the Midtronics Digital Battery Analyzer, J 42000.

^ THE "CCA" READING DISPLAYED ON THE J 42000 SHOULD "NOT" BE COMPARED WITH THE BATTERY'S LABORATORY CCA RATING SHOWN ON THE BATTERY LABEL. THESE NUMBERS ARE NOT RELATED AND ARE ARRIVED AT IN COMPLETELY DIFFERENT WAYS. THE "CCA" NUMBER SHOWN ON THE TESTER WILL JUST ABOUT ALWAYS BE LOWER THAN THE OFFICIAL CCA RATING OF THE BATTERY AND SHOULD NOT BE A CONCERN.

5. Enter the correct CCA of the battery in the vehicle into the Midtronics Tester, J 42000.

6. Test the battery with the Midtronics Digital Battery Analyzer, J 42000. The tester will display one of five messages. Refer to the appropriate message below for the next step.

^ Good battery. (Proceed to the Generator Testing portion of the work sheet).

^ Good-Recharge. (Recharge the battery. Refer to Corporate Bulletin Number 02-06-03-009A Return to Step 4).

^ Charge & retest. In this case, the tester has determined the battery state of charge is too low to perform an adequate test. (Recharge the battery. Refer to Corporate Bulletin Number 02-06-03-009A. Return to Step 4).

^ Replace battery. Return to Step 4.

^ Bad cell - Replace. Go to Step 7.

7. THE "CCA" READING DISPLAYED ON THE J 42000 SHOULD "NOT" BE COMPARED WITH THE BATTERY'S LABORATORY CCA RATING SHOWN ON THE BATTERY LABEL. THESE NUMBERS ARE NOT RELATED AND ARE ARRIVED AT IN COMPLETELY DIFFERENT WAYS. THE "CCA" NUMBER SHOWN ON THE TESTER WILL JUST ABOUT ALWAYS BE LOWER THAN THE OFFICIAL CCA RATING OF THE BATTERY AND SHOULD NOT BE A CONCERN.

If a "Replace Battery" or "Bad cell - Replace" message is displayed on the J 42000, the following steps must be performed before replacing the battery.

^ Disconnect both battery cables.

^ Clean the battery terminal pads.

^ Install test adapters.

Important:
Failure to provide the Midtronics "Out of Vehicle" seven digit test code on the warranty claim may subject the claim to rejection.

^ Perform the Midtronics out of vehicle test.

^ Record the 7 digit code on the repair order and the work sheet.

^ Replace the battery. Return to Step 4 and test the replacement battery.

Important:
THE "CCA" READING DISPLAYED ON THE J 42000 SHOULD "NOT" BE COMPARED WITH THE BATTERY'S LABORATORY CCA RATING SHOWN ON THE BATTERY LABEL. THESE NUMBERS ARE NOT RELATED AND ARE ARRIVED AT IN COMPLETELY DIFFERENT WAYS. THE "CCA" NUMBER SHOWN ON THE TESTER WILL JUST ABOUT ALWAYS BE LOWER THAN THE OFFICIAL CCA RATING OF THE BATTERY AND SHOULD NOT BE A CONCERN.

8. Test the replacement battery with the Midtronics tester J 42000, start with Step 4.





Charging System Test

Shipping Preparation

Please wire tie the following documents to the battery or generator being returned so that they do not become separated in handling.

^ A copy of the Diagnostic Work Sheet.

^ A copy of the repair order.

Warranty Information





For vehicles repaired under warranty, use the table.

N0110 or J4100 labor operation may have the following additional time allowance added to the labor operation time for the component replaced. Use this additional time when the Diagnostic Work Sheet must be completed in order to determine which component needed replacement. ADD: To complete electrical system Diagnostic Worksheet, 0.0 - 0.7 hr.

N9995, Customer Concern, not Duplicated is a Straight Time Labor Operation code, and should be used when the Electrical System Diagnostic Work Sheet test is performed and no trouble is found with the electrical system of the vehicle.

This Labor code has the following note: "Actual time from 0.1 to 0.3 hours spent to perform the diagnosis is to be entered as "Labor Hours" for this operation. Any additional diagnosis time greater than 0.3 hours must be submitted as "Other Labor Hours", and have appropriate Service Management Approval and Authorization.

Leaking batteries are to be claimed using failure code "6J" and do not require a Midtronics test code. The work sheet is not required and the add should not be applied for.

Battery claims, other than leakage, will require the use of the tester and reporting of the tester 7-digit code on the warranty claim.


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