YUASA - The world's leading battery manufacturer

Battery Testing continued
• The battery has lost performance due to external factors,
such as overcharging, undercharging, deep cycling, wear
and tear
These are not manufacturing defects.
REPLACE BATTERY/CELL SHORT CIRCUIT
• Accept Claim
• Battery is defective, replace battery under terms and
conditions of warranty
• Note, if repeated claim from one fleet user, further
investigation of battery usage required especially if the
battery is overdischarging and overcharging
TEST NOT POSSIBLE/CHECK CONNECTION
• Check tester leads (another battery) and ensure terminals
are clean
• Switch off all electrical consumers when testing the battery if
still fitted to the vehicle
• Check Battery Voltage with multimeter, if Voltage > 0 Volts.
Disconnect Battery from vehicle then recharge/retest
NO DISPLAY
• Confirm Battery Voltage = 0 Volts with multimeter
• Accept Claim
B2. SPECIFIC ACID GRAVITY TESTING –
Battery with removable vent plugs
In a good battery the specific acid gravity (sg) should be the
same in all cells. The expected tolerance between all 6 cells is
0.03g/cc (e.g. range of 1.26g/cc to 1.29g/cc).
• After charging a flat battery, insufficient charging may lead to
insufficient mixing of acid above the plates. Using a
multimeter, confirm the stabilised measured voltage
matches the voltage calculated from the specific acid gravity
measurement
• (Average measured specific acid gravity +0.84) x 6 should
be equal to the measured voltage using a digital multimeter.
If not, continue to recharge the battery
Acid Gravity 15°C 1.25-1.28 g/cc Battery Condition Fully
Charged - Proceed with Test
Acid Gravity 15°C 1.20-1.25g/cc Battery partially charged –
Charge before proceeding
Acid Gravity 15°C less than 1.20g/cc Battery low state of
charge – charge immediately, the battery may or may not
recover, subject to period battery left in this low state of charge
B2.1 Has one cell a lower acid gravity than others?
• Example 1.26, 1.25, 1.25, 1.26, 1.26, 1.15
• YES – Accept Claim
• Replace Battery under terms and conditions of warranty
• NO
• Continue to B2.2
B2.2 Is the electrolyte dark brown and/or evidence of
excessive water consumption/topping up?
• YES – Reject Claim
• Damaged caused by overcharging
This is not a manufacturing fault. Check voltage
regulator on vehicle.
• NO
• Continue to B2.3
B2.3 If the specific acid gravity is the same in all cells but
reading lower than 1.25g/cc, charge the battery.
• Is the battery charge acceptance able to achieve the
recommended recharge current, (see catalogue) after 1-2
hours after commencing charging?
• NO – Reject Claim
• Battery badly sulphated due to deep discharging or
undercharging
This is not a manufacturing fault. Check the vehicle
charging system (fan belt tension, alternator
regulator).
• YES
• Complete the recommended recharge
• Continue to B2.4
B2.4 Is the specific acid gravity the same in all cells and above
1.25g/cc?
• NO
• All cells even but less than 1.24g/cc, then extend
recharge by 6 hours
• If one cell has a lower specific acid gravity than others
go back to B2.1
• YES
• Continue to C High Rate Discharge Testing
C HIGH RATE DISCHARGE TESTING
This test should only be carried out if battery voltage > 12.5V,
otherwise recharge battery according to recommended
recharge rates and period (see catalogue)
C1.0 Is the High Rate Discharge Test indicating GOOD Battery?
• YES
• Reject Claim
• NO
• Continue to C2.0
C2.0 Was end of Discharge test showing immediate drop to 0
Volts?
• YES
• Accept Claim (subject to no visual damage to battery)
Manufacturing Defect – Internal Connection break.
Replace battery under terms and conditions of
warranty.
• NO – End of test showed 1.0 Volts to 9.0 Volts
• Reject Claim
This is not a manufacturing defect. Service
deterioration.
Battery Testing
WHEN TO USE A DIGITAL TESTER Voltage CCA vs. Fault and
Check Rating Condition
NEW BATTERY EVALUATION (Before installation) YES NO* YES
WARRANTY CLAIM TEST (After installation) YES YES YES
BATTERY HEALTH CHECK (After installation) YES YES YES
* See Digital Conductance Testers explained
Note: If the battery has been identified as over
discharged, then attempt to recharge, however if
the battery has been left in low state of charge for
period of time, recovery is less likely due to the
deposition of large crystal sulphate formation in
the plates and in the separators which will lead to
grid damage and soft short circuits in the
separator during attempts to recharge.
YUASA - The world's leading battery manufacturer
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