03DelcoRemy Diagnostic Manual130004222020

Page 12 3-5. TEST PROCEDURE Disconnect NOTE If battery has threaded terminals, use terminal adapters or verify you are testing on the lead pads not the threaded terminals. Testing using the studs can create a false bad battery reading. NOTE If you are using an hand held electronic tester, then follow the instructions provide with the tester. Inspect 1. Each battery visually for damage. 2. Electrolyte level. • If fluid is above top of plates in all cells, proceed to step 3. • If fluid is not above top of all plates, add water as required and charge battery for 15 minutes at 15-25 amps to mix electrolyte. Then proceed to step 3. 3. Electrolyte specific gravity with hydrometer at 80˚ F. Readings for all cells should not be less than 1.230. The difference between high and low reading should not exceed 0.050. • If battery meets above requirements, proceed to next test. • If readings show a difference of more than 0.050, replace the battery. • If readings show less than 0.050 difference but one or more cells read less than 1.230, recharge the battery. Remove 1. All battery caps. Test 2. Apply 300 amp load to battery for 15 seconds and turn off load. 3. If blue haze is seen in any cell, replace battery. Otherwise, proceed with next test. Test 1. All batteries passing previous inspections or tests as follows: a. Measure and record electrolyte temperature and replace vent caps. b. Apply test load of 1\2 CCA rating at 0˚F in amps. c. After 15 seconds with load on, measure and record battery terminal voltage. d. Turn load off. e. Check recorded voltage against following table for electrolyte temperature. Temp. 0F 70 60 50 40 30 20 10 0 Min. Volts 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5 f. If recorded voltage does not meet or exceed that in table, replace battery. Otherwise, battery is okay. 3-6. TEST COMPLETION. Clean 1. Cable ends and battery terminals with wire brush. Tighten 1. Battery hold-downs to specifications. NOTE Leave battery cables disconnected and proceed with wiring tests. FIGURE 3-2. Testing Batteries 3-7. BATTERY CABLE TEST WITH SINGLE BATTERY LOCATION (SEE FIGURE 3-3) CAUTION If the vehicle has a combination 12/24-volt system using a series- parallel switch or a T/R alternator, do not use this procedure. Contact BorgWarner Technical Support at 800-372-0222 or email drts@borgwarner.com for information on such systems.