to download CV, PSV, LCV, Agricultural & Plant Catalogue - Yuasa

Battery Testing continuedBattery Testing• The battery has lost performance due to external factors,such as overcharging, undercharging, deep cycling, wearand tearThese are not manufacturing defects.REPLACE BATTERY/CELL SHORT CIRCUIT• Accept Claim• Battery is defective, replace battery under terms andconditions of warranty• Note, if repeated claim from one fleet user, furtherinvestigation of battery usage required especially if thebattery is overdischarging and overchargingTEST NOT POSSIBLE/CHECK CONNECTION• Check tester leads (another battery) and ensure terminalsare clean• Switch off all electrical consumers when testing the battery ifstill fitted to the vehicle• Check Battery Voltage with multimeter, if Voltage > 0 Volts.Disconnect Battery from vehicle then recharge/retestNO DISPLAY• Confirm Battery Voltage = 0 Volts with multimeter• Accept ClaimB2. SPECIFIC ACID GRAVITY TESTING –Battery with removable vent plugsIn a good battery the specific acid gravity (sg) should be thesame in all cells. The expected tolerance between all 6 cells is0.03g/cc (e.g. range of 1.26g/cc to 1.29g/cc).• After charging a flat battery, insufficient charging may lead toinsufficient mixing of acid above the plates. Using amultimeter, confirm the stabilised measured voltagematches the voltage calculated from the specific acid gravitymeasurement• (Average measured specific acid gravity +0.84) x 6 shouldbe equal to the measured voltage using a digital multimeter.If not, continue to recharge the batteryAcid Gravity 15°C 1.25-1.28 g/cc Battery Condition FullyCharged - Proceed with TestAcid Gravity 15°C 1.20-1.25g/cc Battery partially charged– Charge before proceedingAcid Gravity 15°C less than 1.20g/cc Battery low state ofcharge – charge immediately, the battery may or may notrecover, subject to period battery left in this low state of chargeB2.1 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 B2.2B2.2 Is the electrolyte dark brown and/or evidence ofexcessive water consumption/topping up?• YES – Reject Claim• Damaged caused by overchargingThis is not a manufacturing fault. Check voltageregulator on vehicle.• NO• Continue to B2.3B2.3 If the specific acid gravity is the same in all cells butreading lower than 1.25g/cc, charge the battery.• Is the battery charge acceptance able to achieve therecommended recharge current, (see catalogue) after 1-2hours after commencing charging?• NO – Reject Claim• Battery badly sulphated due to deep discharging orunderchargingThis is not a manufacturing fault. Check the vehiclecharging system (fan belt tension, alternatorregulator).• YES• Complete the recommended recharge• Continue to B2.4B2.4 Is the specific acid gravity the same in all cells and above1.25g/cc?• NO• All cells even but less than 1.24g/cc, then extendrecharge by 6 hours• If one cell has a lower specific acid gravity than othersgo back to B2.1• YES• Continue to C High Rate Discharge TestingC HIGH RATE DISCHARGE TESTINGThis test should only be carried out if battery voltage > 12.5V,otherwise recharge battery according to recommendedrecharge rates and period (see catalogue)C1.0 Is the High Rate Discharge Test indicating GOOD Battery?• YES• Reject Claim• NO• Continue to C2.0C2.0 Was end of Discharge test showing immediate drop to 0Volts?• YES• Accept Claim (subject to no visual damage to battery)Manufacturing Defect – Internal Connection break.Replace battery under terms and conditions ofwarranty.• NO – End of test showed 1.0 Volts to 9.0 Volts• Reject ClaimThis is not a manufacturing defect. Servicedeterioration.WHEN TO USE A DIGITAL TESTER Voltage CCA vs. Fault andCheck Rating ConditionNEW BATTERY EVALUATION (Before installation) YES NO* YESWARRANTY CLAIM TEST (After installation) YES YES YESBATTERY HEALTH CHECK (After installation) YES YES YES* See Digital Conductance Testers explainedNote: If the battery has been identified as overdischarged, then attempt to recharge, however ifthe battery has been left in low state of charge forperiod of time, recovery is less likely due to thedeposition of large crystal sulphate formation inthe plates and in the separators which will lead togrid damage and soft short circuits in theseparator during attempts to recharge.508