Battery Checking, Vehicles Without a Battery Monitoring Control Module or Energy Management Control Module
Battery Checking, Vehicles without a Battery Monitoring Control Module or Energy Management Control Module
=> [ Battery Testing, using VAS 6161 ]
=> [ Battery Testing, using VAS 5097A ]
=> [ Measuring the No Load Voltage ]
=> [ Battery Test via Current Draw ]
Maintenance free batteries must not be opened. Otherwise, the warranty is voided.
Battery Testing, using VAS 6161
• When performing the battery test with the battery tester (VAS 6161), the battery ground cable must not be disconnected.
• When using the (VAS 6161) the battery is no longer being charged. The principle of dynamic conductivity measurement is applied. As a result, numerous measurements are possible without recharging the battery.
• The no load voltage measurement can be performed without a waiting period.
• All battery types are stored in the device. They can be refreshed by performing an update.
• The battery barcode can be directly recorded via the optional 2D scanner.
• The integrated temperature sensor increases the quality of the measurements.
• The data can be stored on a SD memory card.
• For information about the (VAS 6161), refer to the operating instructions.
Special tools, testers and auxiliary items required
• Battery Tester (VAS 6161)
• Using the (VAS 6161), refer to the operating instructions.
Procedure
• The battery temperature must be at least 10 °C (50 °F).
CAUTION!
There is a risk of injury from the battery acid.
• Follow accident prevention regulations when working with battery acid. Refer to => [ There is a risk of injury from the
battery acid. ] Lead Acid Battery Warnings and Safety Precautions.
• Wear protective eyewear and clothing. Refer to => [ Protect against injury by using
protective eyewear and clothing. ] Lead Acid Battery Warnings and Safety Precautions.
• On non maintenance free batteries, the sealing plugs must always be firmly tightened during the voltage under load measurement.
Risk of explosion on discharged battery with "visual indicator".
• If the "visual indicator" has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
- Turn off the ignition and all electrical consumers.
- On a battery with a "visual indicator", check its color display. Refer to => [ Electrolyte Level Color, Checking ] Maintenance Free Battery.
- Turn on the (VAS 6161).
- Clamp the red battery tester test clamp "+" to the battery positive terminal or the jump start terminal in the engine compartment.
- Clamp the black battery tester test clamp "-" to the battery ground terminal or the jump start terminal in the engine compartment.
• Make sure the test clamps make good contact!
- Select one of the following:
• Maintenance test
• Service test
• Warranty test
Maintenance Test
- Select "Maintenance Test".
- Connect the scanner and scan in the vehicle identification number.
- Select the connection type: "at the battery terminal" or " at the jump start terminal".
- Select the vehicle model.
- Scan in the battery barcode.
- To determine the temperature, hold the temperature sensor approximately 5 cm above the battery or the jump start terminal until a constant temperature is shown.
- Start the test.
- When necessary, print out the test protocol.
Service Test
- Select "Service Test".
- Select the vehicle model.
- To determine the temperature, hold the temperature sensor approximately 5 cm above the battery until a constant temperature is shown.
- Select the type of battery: "Standard", "AGM ", "2*6V" or "Gel".
- Select the standard: "CCA", "JIS", " DIN", "SAE", "IEC" or "EN".
- Start the test.
- When necessary, print out the test protocol.
Warranty Test
- Select "Warranty Test".
- Select the installed location: "inside the vehicle" or " outside the vehicle".
- Select the vehicle model.
- To determine the temperature, hold the temperature sensor approximately 5 cm above the battery until a constant temperature is shown.
- Select the type of battery: "Standard", "AGM ", "2*6V" or "Gel".
- Select the appropriate capacity with the arrow buttons.
- Start the test.
- When necessary, print out the test protocol.
• The printed test results are required for warranty claims.
- Turn off the battery tester.
- Remove the test clamps.
Test Result on the Printout:
1. Type of test
2. Test result
3. Measured voltage
4. Measured nominal value of the battery
5. Battery nominal value set at the tester
6. Temperature measured above the battery
7. Battery installed location
8. Location of the battery terminal set at the tester
9. Set battery type
• If the battery must be replaced, follow the disposal regulations. Refer to => [ Pollution risk. ] Lead Acid Battery Warnings and Safety Precautions.
Battery Testing, using VAS 5097A
• In the voltage under load measurement, a start procedure at low temperatures is simulated. During the test, a high current is flowing; depending on the battery capacity, voltage must only drop to a minimum value specified by the battery tester.
• Following completion of test, voltage will remain low, and will recover slowly after a period of time.
• If the battery is faulty or only has a weak charge, the battery voltage drops very quickly below the specified minimum voltage.
• If the minimum voltage is not met, the battery must be replaced.
• Perform the test only one time. Repeating the test will not produce accurate results.
• The battery tester must cool off for approximately 30 minutes before it can test another battery.
Using the (VAS 5097 A), 12 V batteries with the follow cold cranking outputs can be tested:
• For information about the (VAS 5097A) operating instructions or the quick reference guide sticker on the device. Refer to the operating instructions.
Special tools, testers and auxiliary items required
• Battery Tester with Printer 5097 A (VAS 5097A)
• Using the battery tester (VAS 5097A), refer to the operating instructions.
Procedure
• The battery temperature must be at least 10 °C (50 °F).
CAUTION!
There is a risk of injury from the battery acid.
• Follow accident prevention regulations when working with battery acid. Refer to => [ There is a risk of injury from the
battery acid. ] Lead Acid Battery Warnings and Safety Precautions.
• Wear protective eyewear and clothing. Refer to => [ Protect against injury by using
protective eyewear and clothing. ] Lead Acid Battery Warnings and Safety Precautions.
• On non maintenance free batteries, the sealing plugs must always be firmly tightened during the voltage under load measurement.
Risk of explosion on discharged battery with "visual indicator".
• If the "visual indicator" has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
- With the ignition turned off, disconnect the ground cable from the battery.
- On a battery with a "visual indicator", check its color display. Refer to => [ Electrolyte Level Color, Checking ] Maintenance Free Battery.
- Determine the Cold Cranking Amps (CCA) according to the specifications on the battery in ampere (A) according to DIN and determine the (VAS 5097 A) adjustment range using the table. Refer to => [ Battery Testing, using VAS 5097A ].
- Set the CCA via the CCA selector switch - 5 -.
- Set the measuring range, 80 - 379 A or 380 - 499 A, using the ON/OFF-function switch - 6 -.
• Batteries with cold cranking output of 520 A according to DIN can be tested with the setting for 499 A according to DIN.
- Clamp the red battery tester test clamp "+" to the battery positive terminal.
- Clamp the black battery tester test clamp "-" to the battery negative terminal.
• Make sure the test clamps make good contact!
• Note TPL 2012182 for (VAS 5097 A).
- Using the sliding switch - 7 -, determine the test clamp connection point.
1. Direct connection to battery.
2. Connection to external test points in engine compartment.
- Check if the cold cranking output indicated on the battery matches the selected value on the battery tester.
- Press the start button - 4 -.
• Green Light Emitting Diode (LED) - 1 - lights up.
• The test program runs automatically.
• The tester result is input from the printer - 9 - after about 20 seconds.
• If the battery tester does not start (no LED lights up, no printout), the battery must be charged. Refer to => [ Battery, Charging ] Battery, Charging.
• If the red LED - 2 - lights up, the battery tester is connected with the terminals reversed.
• If the red LED - 3 - lights up, the battery cannot be tested. Replace the battery.
- Switch the battery tester off with the ON/OFF function switch - 6 -.
- Remove the test clamps.
Test Result on the Printout:
1. Measurement range set on the battery tester
2. Diagram, the - arrow - points to the battery status
3. Test result
4. Battery voltage during the battery load test
5. The technician must enter the vehicle data and date
• If the battery must be replaced, follow the disposal regulations. Refer to => [ Pollution risk. ] Lead Acid Battery Warnings and Safety Precautions.
Measuring the No Load Voltage
• Measuring the no-load voltage, for example, during the prescribed maintenance and service work on vehicles in storage, determines whether the battery must be recharged.
Special tools, testers and auxiliary items required
• Handheld Multi-Meter (V.A.G 1526D)
Procedure
To ensure a correct measurement, the following points must be followed.
• Battery must not be loaded by electrical consumers within the next 2 hours before measurement.
• After battery charging or engine operation, the measurement can be performed only after a 12 hour waiting period.
• The battery temperature must be at least 10 °C (50 °F).
After a waiting period of at least 12 hours:
- Measure the voltage between the battery terminal clamps.
• Specified value: 12.5 volts or higher, the battery is OK.
- If the no load voltage is under 12.5 volts, the battery must be recharged. Refer to => [ Battery Charger, Charging the Battery ] Battery, Charging.
- After charging for 5 minutes, the current draw must be measured again. Refer to => [ Battery Test via Current Draw ].
- If the battery no load voltage is 11.6 volts or lower, the battery is exhaustively discharged.
Battery Test via Current Draw
By checking a battery's current draw capacity during charging, a decision can be quickly made as to whether a partially or exhaustively discharged battery, refer to => [ Exhaustively Discharged Battery ] Battery, Charging can be made usable again by recharging or if it must be replaced.
Special tools, testers and auxiliary items required
• Battery Charger (VAS 5095A) and
• Trigger Clamp 100A (VAS 5051B/7) or
• Battery Charger (VAS 5900) or
• Battery Charger (VAS 5903) or
• Battery Charger (VAS 5904) or
• Battery Charger (VAS 5906)
• When charging with the (VAS 5095A), the battery current draw must be measured, for example, with the (VAS 5051B/7). The battery chargers (VAS 5900), (VAS 5903), (VAS 5904) and (VAS 5906) display the current draw on the device.
• For more information regarding the battery charger, refer to the operating instructions that came with the charger.
Procedure
• The battery temperature must be at least 10 °C (50 °F).
• The battery charger must be able to deliver at least 30 amps (A), for example as with the battery chargers (VAS 5095A), (VAS 5900), (VAS 5903), (VAS 5904) and (VAS 5906).
• Battery charger connected and turned on.
- Measure the battery charge current after 5 minutes of charging.
• Specified value: The charge current must be higher than 10% of the nominal capacity.
• Example: Charge current on a 60 Ah battery after 5 minutes of charging: greater than 6 A.
- If the target value is reached, proceed with the charging operation until the battery is fully charged.
- Then test the battery with the battery tester:
• With the (VAS 6161) without a waiting period. Refer to => [ Battery Testing, using VAS 6161 ].
• With the (VAS 5097A) after a 12 hour waiting period following charging. Refer to => [ Battery Testing, using VAS 5097A ].
- If the specified value is not met, replace the battery.
• If the battery must be replaced, follow the disposal regulations. Refer to => [ Pollution risk. ] Lead Acid Battery Warnings and Safety Precautions.