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3.1.
PREPARATION
Check battery casing for cracks or leakage and confirm whether 6 volts or 12 volts.
3.1.1.
3.1.2.
Clean battery terminals.
3.1.3.
If practical, check electrolyte levels and top up with distilled water as required.
3.2.
CONNECTION
WARNING! Ensure the vehicle or battery is in a well ventilated area before starting to test.
‰
3.2.1.
Attach the positive red clamp to the positive (+) battery terminal. Attach the negative black clamp to the negative (-) battery terminal.
Use the extended clamps if necessary. To ensure good electrical contact twist the clamps on the terminals two or three times. Correct
connection indication will sweep the pointer clockwise across the voltage scale; if connected incorrectly the pointer will sweep
anti clockwise. If there is no movement from the pointer, it is either a bad connection or a dead battery.
3.2.2.
Ensure that the clamp cables are clear of hot or moving engine parts, especially if a starter or charging test is required. Ventilation
slots in the tester casing should not be obstructed and the meter scale easily visible with access to the load switch.
3.3.
BATTERY LOAD TEST
NOTE!
On the first load test, smoke may be emitted from the louvres in the tester casing, this is normal and temporary.
3.3.1.
Press the load switch (red rocker switch on the face of the unit beneath the display) and hold until meter reading stabilises, or for a
maximum of 10 seconds. (Failure to release the switch after 10 seconds may result in the switch burning out and your warranty being
invalidated.) Note the meter reading and then release the load switch.
3.3.2.
Compare the meter reading with load test chart (3.4) to determine battery condition.
NOTES: a)
For 12 volt batteries the green sector (fig.1) border is marked with nominal cranking current from 500 to 1000
amps and stepped in 100 amp intervals. Record this figure and compare with battery manufacturer's quoted figure to give
an indication of any deterioration.
b)
Battery performance falls at low temperatures and quoted cranking amps should be reduced by 50 amps at 20ºF(-7ºC) and
100 amps at 0ºF(-18ºC).
3.4.
LOAD TEST CHART
Load Test Result
OK-Green
12 Volts (fig.1 - 10V Green to 13V
Green CCA)
6 Volts (fig.1 - 4V Green to 8V
Green)
Weak or Bad -yellow or red, but
pointer reading steady.
12 Volts (fig.1 - 8V to 11.4V CCA)
6 Volts (fig.1 - 0V to 5.5V)
Weak or Bad - yellow or red, but
pointer reading falling after 10
seconds on load.
fig.1
3.5.
BATTERY VOLTAGE/CHARGE LEVEL
3.5.1.
If the load test result indicates a battery fault allow battery to stabilise for a few minutes and then read the open circuit voltage - meter reading
with load switch 'Off'.
3.5.2.
Compare the reading with the Voltage/Charge table above right to get an estimation of the charge level.
3.5.3.
The battery is considered charged at 75% or more. If it failed the load test with this charge it should be replaced. If the voltage indicates
a charge level below 75% then charge the battery and load test again. If battery fails this second test replace it.
3.6.
CHARGING SYSTEM (12 VOLT)
3.6.1.
Start engine and allow to reach normal operating temperature. Switch off all accessories.
3.6.2.
Run engine at 1200 to 1500rpm and note meter reading, which should be in the green 'OK' sector (fig.1). DO NOT press the load switch.
3.6.3.
Switch on headlights and heater fan (highest speed), meter reading should remain in the green 'OK' sector.
3.6.4.
A reading in the red sector to the left (fig.1) indicates a fault in the charging system which will cause the battery to be under charged. A
reading in the red sector to the right (fig.1) indicates a fault which will cause the battery to be over charged.
NOTE:
Although not marked on the meter scale the 'OK' range for a 6 volt charging system is 6.8 to 7.5 volts.
© Jack Sealey Limited
Battery Condition
Battery capacity is good. May or may not be fully charged. Check electrolyte specific gravity to
determine charge state. If not fully charged, check for charging system fault (section 3.6) or electrical
drain.
Battery capacity is unsatisfactory. Battery may be either:- (1) defective or (2) partly discharged.
Check electrolyte specific gravity. If over 1.225, the battery is defective. If under 1.225, recharge the
battery and retest. If cell to cell specific gravity varies by more than 0.025 a cell defect may exist. If
charging does not bring specific gravity to full charge level, the battery is either sulphated or has lost
active material.
Battery may be defective. Release load switch and note the meter reaction. If the voltage recovers to 12
volts (6 volts for a 6 volt battery) or more in a few seconds, then the battery is probably defective. If the
voltage recovers slowly the battery may only be discharged. Check the electrolyte specific gravity and
proceed as above
Original Language Version
Open Circuit Voltage
12 volt/6 volt battery
11.7/5.8 or lower
12.0/6.0
12.2/6.1
12.4/6.2
12.6/6.3 or higher
BT91/10.V3 Issue 2 17/03/21
Charge %
0
25
50
75
100
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