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Battery, Mounting and Cables - Battery
Diagnosis and Testing
Principles of Operation Published: 10-Mar-2014
For a detailed description of the battery system and operation, refer to the relevant Description and Operation section of the
workshop manual. REFER to: Battery and Cables (414-01 Battery, Mounting and Cables, Description and Operation).
Inspection and Verification
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not
guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.
NOTES:
Generic scan tools may not read the codes listed, or may read only five digit codes. Match the five digits from the scan
tool to the first five digits of the seven digit code listed to identify the fault (the last two digits give additional information
read by the manufacturer-approved diagnostic system).
When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal
places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads
into account.
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may be the
cause. Always check for loose connections and corroded terminals.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection
Mechanical Electrical
Generator
Drive belt
Drive belt tensioner
Generator pulley
Check the security of the generator fixings
Generator
Battery
Battery connections
Starter motor
Harnesses and connectors
Fuses
Charge warning lamp function
Engine Control Module (ECM)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step.
4. If the cause is not visually evident check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
5. Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific
customer complaint and carry out the recommendations as required
Symptom Chart
Symptom Possible Causes Action
Battery power to vehicle
interrupted
High resistance between battery terminals and
clamps
GO to Pinpoint Test
A. Midtronics EXP-1080 User Guide
Carry out the following: -
Surface Voltage Removal Process
A vehicle which has had its battery charged or been driven in a 24 hour period before the test, must have its surface charge
removed
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1. Turn on the ignition but do not start the vehicle
2. Switch on the headlamps on high beam for a minimum 3 minutes
3. Switch off the headlamps
4. Wait a minimum of 5 minutes before recording test results for any battery measurements
PINPOINT TEST A : VOLTAGE DROP TEST CONDITIONS DETAILS/RESULTS/ACTIONS A1: GROUND CIRCUIT
NOTE: This test checks for high resistance between the battery terminal and the battery clamp 1 Start the engine, turn on the following: (1) ) Air conditioning
(2) ) Blower fan on full speed
(3) Headlights on main beam
(4) Heated screen - rear
(5) Heated screen - front (if installed)
(6) Heated seats (if installed) 2 Connect the multimeter between the battery negative terminal and the battery clamp as shown in picture below (do not
disconnect the battery at this stage) 3 Set the multimeter to read DC voltage and record the reading Is reading equal to or below 0.1 volts? Yes
GO to A2. No
Switch all electrical loads and engine off, return the vehicle to
an ignition off condition. Disconnect the battery negative
clamp, clean clamp and terminal then reconnect and repeat test
GO to A1. A2: POWER CIRCUIT
NOTE: This test checks for high resistance between the battery terminal and the battery clamp 1 Start the engine, turn on the following: (1) ) Air conditioning
(2) ) Blower fan on full speed
(3) Headlights on main beam
(4) Heated screen - rear
(5) Heated screen - front (if installed)
(6) Heated seats (if installed) 2 Connect the multimeter between the battery positive terminal and the battery clamp as shown in picture below (do not
disconnect the battery at this stage) 3 Set the multimeter to read DC voltage and record the reading Is reading equal to or below 0.1 volts? Yes
Carry out midtronics battery test procedure
No
Switch all electrical loads and engine off, return the vehicle to
an ignition off condition. Disconnect the battery power clamp,
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1 LCD screen with main menu 2 Control panel (key board and power button) 3 Positive and negative fly leads 4 Fly leads connection 5 Temperature sensor 6 Infra-red sensor (data transfer for printer) 7 Amp hour 8 Battery rating (CCA) 9 Rating units 10 Battery type
clean clamp and terminal then reconnect and repeat test GO to A2.
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NOTE: Flooded batteries does not have AGM on the label
The following steps must be carried out to ensure correct operation of the EXP-1080 during the battery test procedure
Checks Action Battery fluid leakage, check for battery fluid leaks or damage
to the battery casing
NOTE: If visible damage to the case is evident do not
return battery under warranty
Replace the battery if there is any battery fluid leaks evident Battery vent pipe routing Check for routing, ensure there are no kinks EXP-1080 fly lead, condition of clamps Clean or replace as required EXP-1080 fly lead connection Confirm secure connection
NOTE: The Midtronics EXP-1080 is suitable for testing flooded and absorbed glass mat (AGM) type batteries including
Primary and Secondary batteries
Midtronics Battery Test Procedure
This midtronics battery test procedure will confirm the serviceability of the battery
1. Connect the fly-lead to the midtronics EXP-1080
2. Connect the fly-leads to the battery terminals
- Black lead to negative terminal
- Red lead to positive terminal
- Confirm the connections are secure
3. The EXP-1080 will power on automatically when connected to a battery, screen below is displayed
NOTE: MAIN MENU SCREEN 4.MainMenu.SelectBatterytestandpressSELECT
www.JagDocs.com
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NOTE: BATTERY LOCATION
5. Battery Location
Select Next
6. VIN. When IN VEHICLE selected, enter the last six of the VIN using the key pad
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NOTE:BATTERYRATING
7.BatteryType.Selectthecorrectbatterytype(RegularorAGM)
NOTE:ALLAGMbatteriesaremarked(Refertobatterylabel) Flooded batterieshavenoreferencetobeing Flooded.
SelectNext
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NOTE:
BATTERY
RATING
9.
BATTERY
RATING.
Scroll
using
the
arrow
keys
on
the
midtronics
panel,
select
the
correct
CCA
rating
(For
CCA
refer
to
battery
label)
Select
Next
NOTE:BATTERYTYPE
8.BatteryUnits.Selectthecorrectbatteryratingfromthebatterylabelinbrackets(number9).Scrollusingthearrow
ontheMidtronicspanelandselectNext
NOTE:UNITS
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NOTE:
TESTING
11.
Testing.
The
screen
displays
clock
hand's
rotating,
the
EXP-1080
will
automatically
advance
when
test
has
completed
NOTES:
TEMPERATURE
Ensurethatthetemperaturesensordoesnottouchanypartofthebatteryorvehicle,thiswillcausedamagenotbe
coveredunderthemidtronicswarrantyand willrequiretheunittobereturnedtoaservicecenter
10.Temperature.Aimthetemperaturesensortowardsthebatterycasing (Maintaindistanceof5cm)
SelectNext