ABNORMAL BATTERY DISCHARGING
Any of the following conditions can result in abnormal battery discharging
- A faulty or incorrect charging system component. «(Refer to ELECTRICAL/CHARGING - DIAGNOSIS AND TESTING)»(ref-250642-S17483632802007031500000) for additional charging system diagnosis and testing procedures.
- A faulty or incorrect battery. Use the Micro 420 battery tester and refer to this information for additional battery diagnosis and testing procedures.
- A faulty circuit or component causing excessive ignition-off draw.
- Electrical loads that exceed the output of the charging system. This can be due to equipment installed after manufacture, or repeated short trip use.
- A faulty or incorrect starting system component. «(Refer to ELECTRICAL/STARTING - DIAGNOSIS AND TESTING)»(ref-250629-S07280590432007031500000) for the proper starting system diagnosis and testing procedures.
- Corroded or loose battery posts and/or terminal clamps.
- Slow driving speeds (heavy traffic conditions) or prolonged idling, with high-amperage draw systems in use.
CLEANING
The following information details the recommended cleaning procedures for the battery and related components. In addition to the maintenance schedules found in this information and the owner's manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service.
Scheme 15
Scheme 16
Scheme 17
- Clean the battery cable terminal clamps (2) of all corrosion. Remove any corrosion using a wire terminal brush (1) or a post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution.
- Clean the battery tray and battery hold-down hardware of all corrosion. Remove any corrosion using a wire brush and a sodium bicarbonate (baking soda) and warm water cleaning solution. Paint any exposed bare metal.
- If the removed battery (3) is to be reinstalled, clean the outside of the battery case and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution (2) using a stiff bristle parts cleaning brush (1) to remove any acid film. Rinse the battery with clean water. Ensure that the cleaning solution does not enter the battery cells through the vent holes. If the battery is being replaced, refer to «SPECIFICATIONS»(ref-250654-S25651028352007031500000) for the factory-installed battery specifications. Confirm that the replacement battery is the correct size and has the correct ratings for the vehicle.
- Clean any corrosion from the battery (3) and the battery terminal posts and battery cables (2) with a wire brush or a post and terminal cleaner (1), and a sodium bicarbonate (baking soda) and warm water cleaning solution.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is designed to help dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available, refer to the STANDARD PROCEDURE , which includes the directions for using the Micro 420 battery tester.
| WARNING | IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. |
| WARNING | EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. |
| WARNING | THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN. |
A battery that will not accept a charge is faulty, 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 faulty and must be replaced.
Note. Completely discharged batteries may take several hours to accept a charge. (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE) for the proper battery charging procedures.
CHARGING BATTERY
Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when
- Micro 420 electrical system tester indicates battery is OK.
- All of the battery cells are gassing freely during battery charging.
- Three hydrometer tests, taken at one-hour intervals, indicate no increase in the temperature-corrected specific gravity of the battery electrolyte.
- Open-circuit voltage of the battery is 12.4 volts or above.
| WARNING | NEVER EXCEED TWENTY AMPERES WHEN CHARGING A COLD (-1°C [30°F] OR LOWER) BATTERY. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. |
| WARNING | IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. |
| WARNING | EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. |
| WARNING | THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN. |
| WARNING | IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS, BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS. |
| CAUTION | Always disconnect and isolate the battery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system components may result. |
| CAUTION | Battery electrolyte will bubble inside the battery case during normal battery charging. Electrolyte boiling or being discharged from the battery vents indicates a battery overcharging condition. Immediately reduce the charging rate or turn off the charger to evaluate the battery condition. Damage to the battery may result from overcharging. |
| CAUTION | The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continuing the charging operation. Damage to the battery may result. |
After the battery has been charged to 12.4 volts or greater, perform a load test to determine the battery cranking capacity. (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE) for the proper battery load test procedures. If the battery will endure a load test, return the battery to service. If the battery will not endure 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 ELECTRICAL/BATTERY SYSTEM - CLEANING) for the proper battery system cleaning procedures and (Refer to ELECTRICAL/BATTERY SYSTEM - INSPECTION) for the proper battery system inspection procedures.
CHARGING A COMPLETELY DISCHARGED 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.
Scheme 18
Scheme 18: CHARGING A COMPLETELY DISCHARGED BATTERY
- 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.
- Disconnect and isolate the battery negative cable. Connect the battery charger leads. 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.
- 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»(ref-250654-S38917544502007031500000) 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.
| Voltage | Hours |
|---|
| 16.0 volts maximum | Up to 4 hours |
| 14.0 to 15.9 volts | Up to 8 hours |
| 13.9 volts or less | Up to 16 hours |
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 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.
| Charging Amperage | 5 Amps | 10 Amps | 20 Amps |
|---|
| Open Circuit Voltage | Hours Charging @ 21°C (70°F) |
| 12.25 to 12.49 | 6 hours | 3 hours | 1.5 hours |
| 12.00 to 12.24 | 10 hours | 5 hours | 2.5 hours |
| 10.00 to 11.99 | 14 hours | 7 hours | 3.5 hours |
| Below 10.00 | 18 hours | 9 hours | 4.5 hours |
USING MICRO 420 BATTERY TESTER
Always use the Micro 420 Instruction Manual that was supplied with the tester as a reference. If the Instruction Manual is not available the following procedure can be used
| WARNING | ALWAYS WEAR APPROPRIATE EYE PROTECTION AND USE EXTREME CAUTION WHEN WORKING WITH BATTERIES. |
CHECKING BATTERY ELECTROLYTE LEVEL
The following procedure can be used to check the battery electrolyte level.
Scheme 19
Scheme 19: CHECKING BATTERY ELECTROLYTE LEVEL
Scheme 20
- Remove the battery (2) cell cap (1).
- Look through the battery cap holes (1) to determine the level of the electrolyte in the battery. The electrolyte should be approximately 1 centimeter above the battery plates or until the lip (2) inside the battery cap holes is covered.
- Add only distilled water until the electrolyte level is approximately one centimeter above the plates.
Scheme 21
| 1 - PLASTIC CAP |
|---|
| 2 - POSITIVE BATTERY CABLE |
| 3 - BATTERY HOLD DOWN NUT |
| 4 - NEGATIVE BATTERY CABLE |
| 5 - BATTERY |
| WARNING | WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES. |
- Disconnect the negative battery cable (4). If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.
- Remove the protective plastic cap (1).
- Disconnect the positive battery cable (2). If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.
- Remove the battery hold down nut (3) and strap from the battery.
- Remove the battery (5) from the battery tray.
Scheme 22
| 1 - POSITIVE BATTERY CABLE |
|---|
| 2 - PLASTIC CAP |
| 3 - NEGATIVE BATTERY CABLE |
| 4 - BATTERY |
| 5 - BATTERY HOLD DOWN NUT |
| WARNING | WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES. |
- Disconnect the negative battery cable (3). If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.
- Remove the positive battery cable protective plastic cap (2).
- Disconnect the positive battery cable (1). If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.
- Remove the battery hold down nut (5) and strap from the battery.
- Remove the battery (4) from the battery tray.
LHD
| 1 - PLASTIC CAP |
|---|
| 2 - POSITIVE BATTERY CABLE |
| 3 - BATTERY HOLD DOWN NUT |
| 4 - NEGATIVE BATTERY CABLE |
| 5 - BATTERY |
- Clean and inspect the battery. Refer to the procedures in this information. CAUTION: The battery cable terminal clamps must reach the correct battery terminal post without stretching the cables.
- Position the battery (5) onto the battery tray. Ensure that the battery positive and negative terminal posts are correctly positioned.
- Install the battery hold down onto the battery with the hold down nut (3). Tighten the battery hold down nut to 8 N.m (71 in. lbs.). CAUTION: Be certain that the battery cable terminal clamps are connected to the correct battery terminal posts. Reverse battery polarity may damage electrical components of the vehicle.
- Clean the battery cable terminal clamps and the battery terminal posts.
- Connect the positive battery cable (2). Tighten the terminal clamp pinch-bolt hex nut to 7 N.m (60 in. lbs.).
- Install the positive battery terminal plastic cap (1).
- Connect the negative battery cable (4). Tighten the terminal clamp pinch-bolt hex nut to 7 N.m (60 in. lbs.).
RHD
| 1 - POSITIVE BATTERY CABLE |
|---|
| 2 - PLASTIC CAP |
| 3 - NEGATIVE BATTERY CABLE |
| 4 - BATTERY |
| 5 - BATTERY HOLD DOWN NUT |
- Clean and inspect the battery. Refer to the procedures in this information. CAUTION: The battery cable terminal clamps must reach the correct battery terminal post without stretching the cables.
- Position the battery (4) onto the battery tray. Ensure that the battery positive and negative terminal posts are correctly positioned.
- Install the battery hold down onto the battery with the hold down nut (5). Tighten the battery hold down nut to 8 N.m (71 in. lbs.). CAUTION: Be certain that the battery cable terminal clamps are connected to the correct battery terminal posts. Reverse battery polarity may damage electrical components of the vehicle.
- Clean the battery cable terminal clamps and the battery terminal posts.
- Connect the positive battery cable (1). Tighten the terminal clamp pinch-bolt hex nut to 7 N.m (60 in. lbs.).
- Install the positive battery terminal plastic cap (2).
- Connect the negative battery cable (3). Tighten the terminal clamp pinch-bolt hex nut to 7 N.m (60 in. lbs.).
BATTERY CABLES
A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair.
When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable.
- Remove the battery. «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)»(ref-250654-S00588166142007031500000) .
- Remove the battery tray (1) retaining bolts (2).
- Remove the battery tray (1).
- Install the battery tray (1).
- Install the battery tray (1) retaining bolts (2). Tighten the bolts to 15 N.m (11 ft. lbs.).
- Install the battery. «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(ref-250654-S19712275952007031500000) .
- Install the battery tray (1).
- Install the battery tray (1) retaining bolts (2). Tighten the bolts to 15 N.m (11 ft. lbs.).
- Install the battery. «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(ref-250654-S19712275952007031500000) .
