Part 1
Battery Care
12V LEAD ACID BATTERY CARE MANUAL FOR DEALER / RETAILER USE
1. INTRODUCTION
2. GENERAL RULES FOR BATTERY CARE
3. EQUIPMENT (MINIMUM STANDARD)
4. HEALTH AND SAFETY PRECAUTIONS
5. DETERMINING BATTERY CONDITION
6. BATTERY CHARGING AND MAINTENANCE
7. CHARGING SYSTEM TEST AND DIAGNOSIS
8. VEHICLE QUIESCENT CURRENT TESTING
APPENDIX A: BATTERY TEST PROCESS
APPENDIX B: BATTERY REPORT FORM - IN SERVICE BATTERIES ONLY
1. INTRODUCTION
This publication sets out, for the benefit of dealers / retailers worldwide, requirements for the care and maintenance of batteries, from the vehicles hand-over to the dealer / retailer to the handover to the customer or in the case of a spare part battery from is delivery to the dealer / retailer to its fitment to a customer vehicle.
It applies to all types of 12 volt Lead Acid Batteries used, whether they are conventional flooded technology or Absorbed Glass Mat (AGM) technology and also applies to both Primary and Secondary or Auxiliary Batteries.
The clearly laid out and illustrated sections guide dealers / retailers through each stage of the vehicles or spare parts receipt, storage, pre-delivery and customer hand-over. This publication can be used as a guide to the handling and care of batteries in service. It is vital to appreciate that unless each process is rigorously applied on all vehicles, the customer will receive a vehicle with a battery or a spare part battery which will not provide a satisfactory service life.
It is very important that all tests quoted throughout this publication are adhered to. If they are applied incorrectly batteries could be scrapped unnecessarily. Refer to the battery testing section for detailed information.
It is equally important therefore to note the following key points:
- Most new vehicles leave the factory with either a transit relay installed and/or have a transit mode programmed into the vehicle control modules. The transit relay must be removed and the transit mode disabled (where applicable) using an approved diagnostic system, NOT MORE THAN 24 HOURS before the customer takes delivery.
- 12 Volt Lead Acid Batteries rely on internal chemical processes to create a voltage and deliver current. These processes and the internal chemical structure of the battery can be damaged if the battery is allowed to discharge over a number of weeks / months, or is left in a discharged state for a lengthy time period. For this reason the battery must be tested / re-charged if necessary every month, and MUST BE re-charged after every three month period of storage. Refer to the vehicle storage manual and update the vehicle history sheet.
- Under no circumstances should the battery be disconnected with the engine running because under these conditions the alternator can give a very high output voltage. This high transient voltage will damage the electronic components in the vehicle. Loose or incomplete battery connections may also cause high transient voltage.
- On vehicles with conventional ignition keys, these must not be left in the ignition lock barrel when the transit relay has been removed, otherwise quiescent current will increase and the battery will discharge more rapidly.
- Two types of Lead acid batteries are used; standard Flooded type and AGM (Absorbed Glass Mat) or VRLA (Valve regulated Lead Acid) types. AGM batteries offer improved resistance to cycling as seen in stop start applications. AGM Batteries are fully sealed and cannot have the electrolyte level topped up.
Dealers and retailers involved in the storage, handling of vehicles and spare parts batteries have a responsibility to ensure that only vehicles and spare parts having a fully satisfactory battery may be processed further through the distribution selling chain.
NOTE:
It is very important that test processes quoted throughout this publication are adhered to.
If they are not adhered to correctly batteries could be scrapped unnecessarily or a battery with an issue remains in use. Refer to the battery testing section for detailed information.
2. GENERAL RULES FOR BATTERY CARE
Frequency of Battery Condition Checks.
Any battery in storage whether it is in a vehicle or in spare parts inventory must have its charge status checked every 30 days as described in Appendix A, and must be recharged every 90 days as described in the "Battery Charging and Maintenance" section of this product.
Dealer Demonstration Vehicles
Due to the high depth of discharge a dealer demonstration vehicle battery may experience, batteries that are fitted to vehicles used as dealer demonstration vehicles must be connected to a power supply / charger capable of delivering 50 Amps or more whilst the vehicle is being demonstrated and the engine is not running. This will prevent the battery from being damaged from "energy throughput " wear out during a demonstration.
Software Reflash, SDD work or Ignition On related Workshop Activities.
Due to the high electrical current demand and high depth of Discharge that can occur during vehicle software re-flash activities, SDD work or ignition on related work in the workshop, vehicles that are undergoing such activities MUST have the electrical system on the vehicle supported with a power supply / charger / vehicle maintainer capable of delivering 50 Amps or more.
Jump Starting New vehicles Before They Have Been Delivered to the Customer.
- It is the dealer / retailers responsibility to ensure the battery is not allowed to go flat by following the instructions and processes defined in this product.
- However if circumstances dictate that a new vehicle must be jump started due to a flat battery whilst the vehicle is in the dealer / retailers care, the battery on this vehicle must be replaced with a new one prior to delivery to the customer at the dealer / retailers liability.
- The vehicle should also undergo investigation as to why the battery went flat.
- Do not connect the jump starting cable to the negative (-) terminal of the battery. Always connect to the recommended earthing point. As defined in the owners handbook or service documentation for that vehicle.
Jump Starting or Boost Charging Vehicles in Service
Do not connect the jump starting cable to the negative (-) terminal of the battery. Always connect to the recommended earthing point. As defined in the owners handbook or service documentation for that vehicle.
Charging AGM Batteries
AGM batteries must not be charged with voltages above 14.8 Volts. Doing so will damage them.
Testing AGM Batteries
Midtronics 393, 394, 493 and 494 testers are not capable of testing AGM batteries. Doing so can give an incorrect result.
When it is necessary to test an AGM battery use the Midtronics EXP1080 tester or the GR1 Diagnostics Charger.
3. EQUIPMENT (MINIMUM STANDARD) (pictures are for illustration only)
Traction Battery Charger (or similar stand-alone charger)
Midtronics EXP1080 Hand-Held Tester
Digital Multi-Meter or Digital Volt-Ohm Meter (DVOM)
Midtronics GR-1 Diagnostic Charger
4. HEALTH AND SAFETY PRECAUTIONS
WARNING: BATTERY CELLS CONTAIN SULFURIC ACID AND EXPLOSIVE MIXTURES OF HYDROGEN AND OXYGEN GASES. IT IS THEREFORE ESSENTIAL THAT THE FOLLOWING SAFETY PRECAUTIONS ARE OBSERVED.
WARNING: Batteries emit highly explosive hydrogen at all times, particularly during charging. To prevent any potential form of ignition occurring when working in the vicinity of a battery:
- Do not smoke when working near batteries.
- Avoid sparks, short circuits or other sources of ignition in the battery vicinity.
- Switch off current before making or breaking electrical connections.
- Ensure battery charging area is well ventilated.
- Ensure the charger is switched off when: a) connecting to a battery; b) disconnecting from the battery.
- Always disconnect the ground cable from the battery terminal first and reconnect it last.
WARNING: Batteries contain poisonous and highly corrosive acid. To prevent personal injury, or damage to clothing or the vehicle, the following working practices should be followed when topping up, checking electrolyte specific gravity, removal, refitting or carrying batteries:
- Always wear suitable protective clothing (an apron or similar), safety glasses, a face mask and suitable gloves.
- If acid is spilled or splashed onto clothing or the body, it must be neutralized immediately and then rinsed with clean water. A solution of baking soda or household ammonia and water may be used as a neutralizer.
- In the event of contact with the skin, drench the affected area with water. In the case of contact with the eyes, bathe the affected area with cool clean water for approximately 15 minutes and seek urgent medical attention.
- If battery acid is spilled or splashed on any surface of a vehicle, it should be neutralized and rinsed with clean water.
- Heat is generated when acid is mixed with water. If it becomes necessary to prepare electrolyte of a desired specific gravity, SLOWLY pour the concentrated acid into water (not water into acid), adding small amounts of acid while stirring. Allow the electrolyte to cool if noticeable heat develops. With the exception of lead or lead-lined containers, always use non-metallic receptacles or funnels. Do not store acid in excessively warm locations or in direct sunlight.
WARNING: Due to their hazardous contents, the disposal of batteries is strictly controlled. When a battery is scrapped, ensure it is disposed of safely, complying with local environmental regulations. If in doubt, contact your local authority for advice on disposal facilities.
5. DETERMINING BATTERY CONDITION
The tools used for determining the condition of the battery will depend upon whether it is installed in a vehicle or in spare parts inventory. Concerning an installed battery, procedures will vary if the vehicle is new, or already in service with a customer.
NOTE:
The term `New Vehicle' refers to a vehicle at any part of the delivery process from leaving the factory to arriving at a port of entry, dealership, retailer, including any storage facilities en route or a vehicle being stored prior to sale at dealership / retailer.
NOTE:
Midtronics 393, 394. 493 and 494 testers must not be used to test AGM batteries as these testers are not capable of correctly testing AGM batteries and can give an incorrect result. For AGM battery testing use the EXP1080 tester or the GR1 Diagnostics charger.
NEW VEHICLES
A Midtronics tester should be used to assess the condition of the battery for new vehicles. The test results should be recorded on the Storage History Sheet (see Vehicle Storage manual).
Scenario 1 - Dealership / Retailer (Responsibility: Dealer / Retailer)
1. Within 24 hours of arrival at the dealer / retailer proceed as follows:
- Perform a Midtronics battery test (See Appendix A.)
- Carry out the recommended actions accordingly.
2. If the Midtronics result is "Good Battery" the vehicle may be stored.
- For all new vehicles in storage the transit relay MUST be fitted, or the Transit Mode enabled where used. For vehicles without a transit relay or a Transit Mode, the battery negative cable MUST BE DISCONNECTED from the battery.
3. The battery must be tested and/or re-charged every month and MUST be re-charged after every three month period.
4. Record your test results on the Storage History Sheet (see Vehicle Storage Manual) to indicate when a re-charge will be necessary.
Scenario 2 - Delivery to the Customer (Responsibility: Dealer / Retailer)
NOTE:
It is essential that the following actions are conducted in the 24 hours prior to the agreed hand over time:
1. Perform a Midtronics Battery test (See Appendix A).
2. Carry out the recommended actions accordingly.
3. The vehicle should only be released to the customer if Midtronics has tested the battery as "Good Battery"
Spare Part Batteries
Lead acid batteries will, as a result of natural chemical processes, slowly self discharge themselves over a period of time (even when open circuit and no electrical load applied).
In the case of spare parts batteries, a Midtronics tester should be used to assess the condition of new spare parts batteries.
The batteries must be stored such that they cannot get wet and are not in direct sunlight.
Any batteries which are dropped must be scrapped. This applies even if no external damage is apparent.
Scenario 1 - Spare Part Batteries Within Dealer Stock But Not Yet Fitted To A Vehicle (Responsibility: Dealer / Retailer)
1. For a battery in the Dealer parts or in ready to use stock but not yet fitted to a vehicle the following rules must be followed:
- Check the battery condition on receipt by performing a Midtronics battery test (See Appendix A).
- Batteries should only be returned to storage if the Midtronics tester indicates "Good Battery".
- The battery condition should be rechecked every 30 days by performing a Midtronics battery test (See Appendix A).
- If required batteries should be recharged as described in the "Battery Charging and Maintenance" section of this product.
2. 2 All batteries must be controlled via a FIFO (First In First Out) process to ensure aged batteries are not held and the batteries are not allowed to age unnecessarily.
VEHICLES IN SERVICE
The Midtronics hand-held tester or the Midtronics Diagnostic Charger are the preferred tools to assess battery condition for vehicles in service. The test results should be recorded on the In-Service Battery Report Form (See Appendix B).
Midtronics Testing - In-Service Testing Only
NOTE:
The battery surface charge must be removed before this test in accordance with the procedure in Appendix A. Ensure that the battery terminal connectors are clean. When connecting the Midtronics testing equipment, connect the RED clip to the positive (+) battery terminal first, and then connect the BLACK clip to the negative (-) battery terminal. Rock the clips backward and forward to ensure a good connection to the battery.
1. Perform a Midtronics battery test (See Appendix A).
2. Carry out the recommended actions accordingly.
6. BATTERY CHARGING AND MAINTENANCE
BATTERY CHARGING
It is essential that a suitably ventilated defined area exists in each dealership / retailer for battery charging. Likewise, an area should be allotted for scrap batteries, and clearly indicated as such. It is recommended that dealers / retailers always have fully charged batteries ready for use. However the battery MUST BE tested and charged if necessary every month, and charged after three months irrespective of any test.
CAUTION: Batteries must be re-charged after a maximum of 3 months storage (see Storage History sheet in the New Vehicle Storage Manual).
CAUTION: It is very important that when charging batteries using the traction charger or other stand-alone chargers that the charger is set for the correct type of battery before charging commences. If the wrong switch is selected the result would be a battery that is not charged fully and / or overheating can occur. Follow the manufacturers operating instructions.
CAUTION: Do not charge AGM batteries with voltages over 14.8 volts as this will damage the battery.
To bring a serviceable but discharged battery back to a fully charged condition proceed as follows:
- Check and if necessary top-up the battery electrolyte level.
- Charge the battery using the Midtronics Diagnostic Charger (USA) or Traction Charger (all other markets) following the manufacturers operating instructions.
NOTE:
When using the Midtronics Diagnostic Charger, automatic mode must always be used. After charging and analysis, the charger may display 'Top-Off Charging', press STOP to end. Do not stop charging until the current falls to 5A or less, otherwise the battery will not be fully charged.
POST-CHARGE TEST METHODS
New Batteries, Batteries in Storage and In-Service Batteries
The purpose of this test is to ensure that the charging process has fully charged the battery.
NOTE:
IT IS RECOMMENDED THAT THIS TEST IS CONDUCTED AT LEAST 24 HOURS AFTER THE CHARGE CYCLE IS COMPLETED.
CAUTION: DO NOT connect the tester to any other circuit or chassis point.
1. Attach the Midtronics Tester to the battery.
2. Follow the instructions on the tester to test the battery. Ensure the correct battery type and size is selected.
3. Perform the action based on the tester results (see the tester results chart in the Vehicles in Service sub -section of Determining Battery Condition Section).
4. Enter the readings and test code obtained on the In Service Battery Report Form.
NOTE:
Midtronics 393, 394. 493 and 494 testers must not be used to test AGM batteries as these testers are not capable of correctly testing AGM batteries and can give an incorrect result. For AGM battery testing use the EXP1080 tester or the GR1 Diagnostics charger.