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14
BATTERIES
BATTERY TESTING
See General Warning, Section 10, Page 10-1.
Four tests have been developed to help diagnose problems with batteries that have not performed as
expected. Because each test becomes progressively more detailed and time-consuming, begin with the first
test and follow through with the other tests until the problem has been identified as outlined in the Battery
Troubleshooting Chart (Figure 14-5, Page 14-9).
BATTERY CHARGER TEST
The easiest way to monitor the condition of a vehicle's batteries is simply to observe the reading on the battery
charger ammeter at the end of the charge cycle. After a full charge, disconnect the charger DC plug, wait 20
to 30 seconds and reconnect the charger DC plug. The ammeter needle will jump to 15 amps or more and
then taper to below 6 amps within 10 to 20 minutes, indicating sound, fully charged batteries.
Continued poor performance may indicate a problem in the vehicle electrical system, brakes or battery
charger. If the problem is not found in the vehicle or charging system, proceed to the on-charge voltage test.
Batteries that remain at 8 amps or higher should be tested further using the on-charge voltage test.
ON-CHARGE VOLTAGE TEST
When the batteries are fully charged, disconnect the charger DC plug. Wait 20 to 30 seconds and reconnect
the DC plug to restart the charger. After 5 minutes, use a multimeter to check and record the voltage of the
battery set as well as the individual batteries. Set the multimeter to 200 volts DC. Place the red (+) probe on
the positive (+) post of battery no. 1 and the black (–) probe on the negative (–) post of battery no. 8. Record
reading. Then set multimeter to 20 volts DC and place the red (+) probe on the positive (+) post and the black
(–) probe at the negative (–) post of each battery. Record the readings.
The on-charge voltage for the set should be between 56.0 volts and 63.0 volts depending on the age and state
of charge of the batteries being tested. If individual batteries read above 7.0 volts and are within 0.5 volts of
each other, go to the hydrometer test. If any battery reads below 7.0 volts and not within 0.5 volts of those bat-
teries above 7.0 volts, replace battery. If readings are below 7.0 volts but within 0.5 volts of each other, the
batteries are old. Old batteries may have enough capacity left to last several more months. Go to hydrometer
test. See Battery Troubleshooting Chart on page 14-9 and the examples on the following pages.
HYDROMETER TEST
CAUT ION
• Do not allow battery acid from battery caps or hydrometer to drip onto the front or rear body
of the vehicle. Battery acid will cause permanent damage. Wash immediately.
A hydrometer measures the specific gravity of the battery's electrolyte. The higher the specific gravity, the
higher the state of charge of the batteries. A fully charged battery should read between 1.250 and 1.280 at
80 °F (26.7 °C). Never add acid to batteries to obtain a higher specific gravity.
Performing the Hydrometer Test
1. Be sure batteries have sufficient electrolyte to cover plates by approximately 1/2 inch (13 mm) and are
fully charged prior to beginning test. If water must be added, recharge the batteries before performing the
hydrometer test.
2. Remove the vent cap. Using a battery thermometer (CC P/N 1011767), record electrolyte temperature
of the no. 2 cell.
Page 14-10
2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement
Battery Testing
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Troubleshooting
