1. Introduction
This publication is intended for dealers/retailers worldwide and sets out requirements for the care and maintenance of batteries from the time vehicles are handed over to the dealer/retailer to the time they are handed over to the customer or, in the case of a replacement battery, from the time they are delivered to the dealer/retailer to the time they are installed in the vehicle. client.
It applies to all types of 12 Volt lead-acid batteries in use, whether they use standard flood technology or glass microfiber absorbent baffle technology (AGM), and also applies to both primary and secondary or auxiliary batteries.
In clearly laid out and illustrated sections, dealers/retailers will be provided with information on all stages of receiving, storing, pre-sale preparation and transfer of vehicles and spare parts to the customer. This manual can be used as a reference for battery maintenance and care. It must be clearly understood that if all battery maintenance requirements for each vehicle are not met, the customer will receive a vehicle with a battery or a spare battery that will not provide proper performance and service life.
It is very important to strictly adhere to all the checks given in this document. Batteries will quickly fail if not used properly. See the Battery Testing section for more details.
Also note the following key points:
- Most vehicles shipped from the factory have a transit relay and/or transit mode programmed into the vehicle's control units. This transit relay must be removed and the transit mode deactivated (if applicable) using a certified diagnostic system NOT LATE THAN 24 HOURS before the vehicle is handed over to the buyer;
- 12 volt lead acid batteries rely on internal chemistry to create voltage and current. These processes and the battery's internal chemistry can be damaged if the battery is discharged for weeks/months or if it is left in a discharged state for a long time. Therefore, the battery should be checked and, if necessary, recharged monthly, and after three months of storage, recharging should be carried out MANDATORY. Refer to the car storage manual and make an entry in the car's service book;
- Do not disconnect the battery while the engine is running, as this could cause a very high voltage output from the alternator. High transient voltage will damage the vehicle's electronic equipment. Loose or incomplete battery cables can also cause high transient voltage;
- in cars with traditional ignition keys, it is forbidden to leave the key in the ignition after removing the transit relay, since in this case the quiescent current will increase and the battery will be discharged much faster;
- Two types of lead-acid batteries are used: standard flooded and AGM type (with absorbent glass microfibre baffles) or VRLA (lead acid, valve regulated). AGM batteries have increased resistance to cyclic loads seen during stop and start. AGM batteries are completely sealed and cannot be topped up with electrolyte.
Dealers and retailers who store and transport vehicles and spare batteries are responsible for ensuring that only vehicles and parts with fully functional batteries are allowed to be further distributed through the distribution chain.
NOTE: It is very important that all test procedures in this document be strictly adhered to. If they are violated, the batteries may unreasonably become unusable or it is possible to continue to operate a battery that is not fully functional. See the Battery Testing section for more details.
2. General rules for battery care
Frequency of battery health checks
Any battery in storage, whether on a vehicle or as a spare part, must be tested for state of charge every 30 days as described in Appendix A, and must be recharged every 90 days as described in section "Charging and maintaining the battery" this guide.
Dealer demo vehicles
Due to the high rate of discharge that a dealer's show car battery can experience, show car batteries must be connected to a power source/charger capable of delivering 50 amps or more when the car is shown with the engine off. This will prevent damage to the battery due to wear and tear caused by the energy output during the demonstration.
Workshop activities related to software reinstallation, SDD operation, or ignition on
Due to the high electrical demand and high discharge rate that can occur during software re-installation, SDD operation, or ignition-related work, the electrical system of vehicles where such work is performed MUST be connected to a power source/charger/ a battery charger capable of supplying at least 50 A.
Starting new cars from an external battery before delivery to the customer.
- It is the responsibility of the dealer/retailers to prevent battery drain by following the instructions and procedures in this manual.
- However, if circumstances require a new vehicle to be started from an external battery due to the battery being depleted while the vehicle is at the dealer/retailer, the battery must be replaced with a new one before being handed over to the customer at the dealer/retailer's expense.
- It is also necessary to check the car to find out the cause of the battery discharge.
- Do not connect the jump start cable to the negative (-) battery terminal. Always connect to the recommended point "masses". As described in the owner's manual or service documentation for that vehicle.
Forced charging or starting a serviced vehicle from an external battery
Do not connect the jump start cable to the negative (-) battery terminal. Always connect to the recommended point "masses". As described in the owner's manual or service documentation for that vehicle.
Charging AGM batteries
AGM batteries must not be charged using voltages higher than 14.8 V. Doing so will damage them.
Checking AGM batteries
Midtronics 393, 394, 493 and 494 testers are not suitable for testing AGM batteries. Using them may result in incorrect results.
If an AGM battery test is required, use the Midtronics EXP1080 tester or the GR1 Diagnostic Charger.
3. Equipment (standard minimum)
Traction battery charger (or similar battery charger)
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Midtronics EXP1080 Handheld Tester
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Digital multimeter or digital volt/ohmmeter (DVOM)
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Midtronics GR-1 Diagnostic Charger
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4. Health and safety precautions
Warning: Battery cells contain sulfuric acid and an explosive mixture of hydrogen and oxygen. therefore, the following safety precautions must be strictly observed.
Warning: Batteries constantly emit explosive hydrogen, especially during charging. To prevent a potential fire hazard when working near the battery:
- do not smoke near batteries;
- do not allow sparks, short circuits or other sources of fire near the battery;
- when disconnecting / connecting conductive cables, be sure to turn off the current beforehand;
- Provide adequate ventilation in the battery charging area.
- The charger must be turned off in the following cases: a) when connected to a battery; b) disconnected from the battery.
- Ground wire ("weight") be sure to disconnect from the battery first and connect last.
Warning: Batteries contain poisonous and highly corrosive acid. To prevent personal injury or damage to clothing or the vehicle, the following procedures must be followed when topping up, checking electrolyte specific gravity, or removing, installing, or carrying batteries:
- be sure to wear appropriate protective clothing (apron or similar protective equipment), goggles, face shield and suitable gloves;
- If acid gets on clothing or on the body, it must be neutralized immediately and then washed off with clean water. As a neutralizer, you can use a solution of baking soda or household ammonia;
- in case of acid contact with the skin, the affected area should be thoroughly washed with water. In case of contact with eyes, flush the affected area with cold clean water for about 15 minutes, then seek medical attention immediately;
- if acid from the battery gets on any parts of the car, it must be neutralized and washed with clean water;
- When acid is mixed with water, heat is released. If you want to prepare an electrolyte with a certain specific gravity, SLOWLY and little by little pour the concentrated acid into the water (not water to acid), while constantly stirring the solution. If the electrolyte becomes noticeably warm, allow it to cool. Be sure to use non-metallic containers and/or funnels (the exception may be tanks made of lead or lead-lined). Do not store acid in places with excessively high temperatures or in direct sunlight.
Warning: Disposal of rechargeable batteries due to their high environmental hazard is strictly regulated. In the event of a battery failure, be sure to follow the safety precautions for disposal of the battery in accordance with local environmental laws. In case of any doubt, please contact your local authorities for information on recycling organizations.
5. Determine battery status
The list of tools used to determine the condition of the battery depends on whether the battery is installed on the car or is a spare part. With regard to the installed battery, the procedures differ if the vehicle is new or already in use by the customer.
NOTE: Term "new car" means a vehicle at any stage of the delivery process from leaving the factory to arrival at the port of destination, dealership, retailer, including all storage facilities along the route and storage of the vehicle prior to sale at the dealership/retailer.
NOTE: The Midtronics 393, 394, 493, and 494 testers must not be used to test AGM batteries as they are not suitable for testing AGM batteries and may give incorrect results. To test the AGM battery, use the EXP1080 tester or the GR1 diagnostic charger.
New cars
A Midtronics battery tester should be used to evaluate the battery condition of new vehicles. The results of the check should be recorded in the warehouse form (see car storage guide).
Scenario 1 - Dealership / Retailer (responsibility: dealer / retailer)
1. Within 24 hours of delivery to the dealer/retailer, do the following:
- Perform a battery test with a Midtronics tester (see appendix A).
- follow the appropriate recommendations.
2. If the Midtronics test result is "battery is good", the car can be stored.
- All new vehicles in storage MUST have a transit relay installed or transit mode enabled if used. On vehicles without a bypass relay and bypass mode, the negative battery cable MUST BE DISCONNECTED from the battery.
3. The battery should be checked and/or recharged monthly, and MANDATORY recharged every three months.
4. Record the results of inspections on the warehouse form (see car storage guide), so that you can easily determine the time of mandatory recharging.
Scenario 2 - delivery to the buyer (responsibility: dealer / retailer)
NOTE: The following procedures must be completed within 24 hours prior to the agreed transfer time:
1. Perform a battery test using a Midtronics tester (see appendix A).
2. follow the appropriate recommendations.
3. The car must be handed over to the buyer only if the result is obtained when checking the battery with a tester "battery is good".
Spare batteries
Lead acid batteries will slowly discharge over time due to natural chemical processes (even when the circuit is open and there is no electrical load).
For replacement batteries, a Midtronics tester must be used to check the condition of the new replacement batteries.
Batteries must be stored in a dry place out of direct sunlight.
All dropped batteries must be disposed of. This is a mandatory requirement even in the absence of obvious external damage.
Scenario 1 - Spare batteries in dealer stock not yet fitted to vehicle (responsibility: dealer / retailer)
1. For a battery that is a dealer part or a ready-to-use part not yet installed on the vehicle, the following rules must be observed:
- Check battery condition upon receipt by running a Midtronics test (see appendix A).
- Batteries should only be returned to storage if the Midtronics tester has shown a result "battery is good".
- Battery condition must be checked every 30 days by performing a Midtronics test (see appendix A).
- If necessary, recharge the batteries according to the instructions in section "Charging and maintaining the battery" this guide.
2. 2 All batteries must be distributed according to the FIFO method (in order of priority), so that older batteries are not kept in stock and all batteries are not aged unnecessarily.
Operated vehicles
The use of the Midtronics Handheld Tester or the Midtronics Diagnostic Charger is recommended to determine the battery condition of current vehicles. The test results should be recorded in the form "Vehicle Batteries Report" (see annex B).
Midtronics test - test used batteries only
NOTE: Prior to beginning this test, the battery surface charge must be removed as indicated in Appendix A. Make sure the battery terminals are clean. When connecting the Midtronics tester, first connect the RED clamp to the positive (+) battery terminal, then BLACK negative (-) battery terminal. Rock the clamps back and forth to check for good contact with the battery terminals.
1. Perform a Midtronics Battery Test (see appendix A).
2. follow the appropriate recommendations.
6. Battery charging and maintenance
Charging the battery
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The dealer/retailer must have a dedicated, well ventilated area for battery charging. Likewise, defective batteries should have a designated area marked accordingly. Dealers/retailers are advised to keep fully charged, ready-to-use batteries in stock at all times. However, the vehicle battery MUST be checked and recharged once a month and charged once every three months regardless of the results of the checks.
Caveats:
- Batteries should be recharged at least once every 3 months during storage (see section "warehouse form" in the New Car Storage Guide).
- When using a traction battery charger or other stand-alone chargers, it is very important to set the charger to the correct battery type before charging. If the switch position is incorrect, the battery will not be fully charged and/or the battery may overheat. Follow the manufacturer's instructions for use.
- Do not charge AGM batteries using voltages higher than 14.8V as this will damage the battery.
To restore a healthy but completely discharged battery to a healthy state, do the following:
- Check the electrolyte level and top up if necessary.
- Charge the Battery with the Midtronics Diagnostic Charger (USA) or charger for traction batteries (other countries), following the manufacturer's operating instructions.
NOTE: When using the Midtronics diagnostic charger, you must always use automatic mode. After charging and analysis, a message may appear on the charger "Top-Off Charging" (Charging completed), press STOP to stop. Do not stop charging until the current drops to 5A or less. Otherwise, the battery will not be fully charged.
Check methods after charging
New batteries, batteries in stock and used batteries.
The purpose of this test is to check if the battery is fully charged during charging.
NOTE: It is recommended that this test be performed at least 24 hours after charging is complete.
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CAUTION: DO NOT connect the tester to other circuits or chassis points.
1. Connect the Midtronics tester to the battery.
2. Follow the tester's instructions to check the battery. Be sure to select the battery type and size.
3. Perform the necessary actions depending on the results of the tester (see tester results table in subsection "Operated vehicles" section "Determining battery health").
4. Enter your readings and test result code into "Vehicle Batteries Report".
NOTE: The Midtronics 393, 394, 493, and 494 testers must not be used to test AGM batteries as they are not suitable for testing AGM batteries and may give incorrect results. To test the AGM battery, use the EXP1080 tester or the GR1 diagnostic charger.
Replacing the battery
If the battery is determined to need replacement, be sure to refer to the appropriate section in the workshop manual for removing and installing the battery from the vehicle.
On used vehicles equipped with a battery monitoring system (BMS), after installing a new battery, the BMS module should be rebooted. The BMS module reset procedure should be performed using the recommended diagnostic system.
Checking/topping up battery electrolyte - only applies to certain types of flooded batteries.
Warnings:
- Batteries using agm technology are fully sealed for life and no attempt should be made to check or top up the electrolyte level.
- Read the Health and Safety Precautions section before checking and adding electrolyte.
Make sure that the type of battery provides for topping up the electrolyte. On the top panel of these types of batteries there are plugs or a removable cover, under which there are banks.
If the battery case is transparent or translucent with level marks, visually check the maximum level indicator on the case to make sure that it shows a sufficient level of electrolyte above the separators in the battery.
If the battery case is black, remove the caps from the cans or the overall cap and check the electrolyte level against the indicator in the opening of the can. A flashlight may be needed to check the electrolyte level in these types of batteries.
CAUTION: DO NOT POUR ABOVE the required level.
If the electrolyte level is low, add distilled water.
Maintenance free and valve regulated batteries (AGM), are sealed, so topping up the electrolyte is not possible.
Testing and diagnostics of the charging system
For all vehicles see "Charging system - diagnostics and verification" in section 414-00 of the repair manual.
Checking the quiescent current
NOTE: On vehicles equipped with a battery monitoring system (BMS), use the diagnostic procedure to check for quiescent current leakage using the recommended diagnostic system.
NOTE: If a customer complains of continuous battery discharge or discharging after prolonged non-use, it is recommended to perform a quiescent current leakage test as described below.
NOTE: Battery discharge should be measured using the recommended diagnostic system or a digital multimeter (DVOM). The car must be locked, be in security mode (those. alarm is fully on), all doors, hood, trunk lid are open and locked (they should look electrically closed). The test should be carried out after the vehicle has gone into full shutdown mode. The time required for this after switching off the ignition depends on the model - see "Static discharge" in section 414-00 of the repair manual.
NOTE: When the car alarm is on, flashing the alarm LED will cause a ripple in the measured leakage current. In this case, you should get the average value of the current strength (to do this, use a digital multimeter with the function of calculating the average value), or use the obtained current value without taking into account short-term peak values.
Equipment
Recommended diagnostic system with current probe or digital multimeter (DVOM) with a probe for measuring current.
Using the recommended diagnostic system
- 1. Turn off all electrical consumers and ignition.
- 2. Connect the current probe to the certified diagnostic system.
- 3. Calibrate the probe.
- 4. Install the clamp on the battery wire/terminal box wire.
- 5. Go to the section "Checking the quiescent current".
Using a digital multimeter (DVOM).
NOTE: Do not use a linear digital multimeter to measure quiescent current leakage on vehicles equipped with electronic throttle. The current exceeds the maximum value for which the DMM fuse is rated.
- 1. Turn off all electrical consumers and ignition.
- 2. Connect the current probe to the digital multimeter.
- 3. Calibrate the probe.
- 4. Install the clamp on the battery wire/terminal box wire.
- 5. Proceed to the next section "Checking the quiescent current".
Checking the quiescent current
- 1. Turn on the ignition or select the ignition mode (on vehicles equipped with a keyless entry system), then turn off (without starting the engine).
- 2. Remove the key from the ignition (if applicable).
- 3. Open and lock all doors, hood and trunk lid.
- 4. Lock the car with the remote control. (Only locking, so that the surround alarm does not turn on).
- 5. Remove any other potential current sinks such as accessories included in the connector.
- 6. Record the ampere reading after the shutdown period has elapsed. See subsection for static discharge ampere readings for each model "Static discharge" in section 414-00 repair manual
- 7. Record the final value on the Appendix B Battery Status Report.
NOTE: In case of excessive current consumption, it is recommended to use the following test method: connect the probe in turn to each individual wire of the terminal box leading to potentially faulty circuits, identify the source of the fault. This method is preferred over the previous fuse removal method for the following reasons:
- many modules take a considerable amount of time to shut down completely. By removing and then installing the fuses, the quiescent current leakage value stabilizes for a long time (usually up to 45 minutes).
- leakage can be caused by an unpowered module that prevents the quiescent current leakage from decreasing to a normal level;
- leakage can be caused by an activated relay coil. When the fuse is removed, «reset», and the leak may not be registered by the diagnostic system.
Appendix A. Battery Test Method
It is recommended to perform this test at least 24 hours after turning off the engine or charging the battery to eliminate the need to remove the surface charge, if there are time limits, perform a charge removal.
Part 1 - Removing the Surface Charge
NOTE: Before testing the battery, make sure there is no surface charge on the battery.
NOTE: The battery test can be done on a workbench or directly on the vehicle.
If the test is performed on a car, then before taking a measurement, the battery should be isolated from the car by disconnecting the negative terminal from its terminal (-) the wire. The exception is when the vehicle is equipped with a transport relay or the vehicle is in transport mode.
If the vehicle's battery was charged or the vehicle was operated within 24 hours prior to the start of the test, the surface charge must be removed from the vehicle using one of the following methods:
- 1. If 24 hours have passed since the last engine start or battery charge, go to "Parts 2 - battery check".
- 2. Turn on the ignition. Turn on high beam headlights for at least 3 minutes.
- 3. Turn off the headlights. On vehicles being tested after removing the transit relay, disconnect the battery by removing the negative (-) cable. Vehicles with a transport relay installed or low current transport mode enabled do not require the battery to be disconnected.
- 4. Wait no more than 5 minutes before recording any battery test results.
Part 2 - battery check
NOTE: Prior to starting this test, the surface charge of the battery must be removed as described in part 1 above. Make sure the battery terminals are not dirty. When connecting the Midtronics tester, first connect the RED clamp to the positive (+) battery terminal, then BLACK negative (-) battery terminal. Rock the clamps back and forth to check for good contact with the battery terminals.
NOTE: The Midtronics 393, 394, 493, and 494 testers must not be used to test AGM batteries as they are not suitable for testing AGM batteries and may give incorrect results. To test the AGM battery, use the EXP1080 tester or the GR1 diagnostic charger.
CAUTION: DO NOT connect the tester to any other circuit or chassis point other than the negative battery terminal.
- 1. Connect the Midtronics tester to the battery.
- 2. Follow the tester's instructions to test the battery. Be sure to select the battery type and size.
- 3. Perform the actions required by the results of the check (see table below).
- 4. Enter the readings and the resulting verification code on the battery reporting form (Appendix B) or similar form, where at least the following data is recorded: the name of the technician, vehicle identification number (VIN), test date, Midtronics code and battery voltage according to Midtronics tester.
Upon completion of the test, negative (-) the battery cable should be connected to the battery terminal.
RESULTS OBTAINED WITH THE TESTER | ACTION |
GOOD BATTERY (Battery is OK) | Return to service. |
GOOD RE-CHARGE (Battery OK, needs charging) | Fully charge the battery and return it to service. |
CHARGE AND RETEST (Charge and retest) | Fully charge the battery. Remove surface charge. Repeat battery test. If the result does not change, replace the battery. |
REPLACE BATTERY OR BATTERY IS DEFECTIVE | Make sure the surface charge is removed. Disconnect the battery from the vehicle and recheck. If the result does not change after removing the surface charge, replace the battery. DO NOT RECHARGE. |
UNABLE TO DO TEST (Unable to perform verification) | Disconnect the battery from the vehicle and recheck. |
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