Battery - Service Procedures
SECTION: 86No: 56
BATTERIES
Model: 1990 MY SEDANS Date: SEPTEMBER, 1989
KEYPOINTS: BATTERY SERVICE
The 1990 M.Y. sedan range vehicles will incorporate a type 440 battery providing improved recovery capabilities when subjected to deep cycle discharge. This will ensure that the state of charge will be higher under all operating conditions at all times.
Improved battery recovery capability is due to an increase of electrolyte from 2.5 quarts to 2.75 quarts.
This electrolyte quantity change required a reduction in reserve capacity from 110 min @ 63 Ahr to 75 min @ 50 Ahr; and a reduction in cold cranking amperage from 520A to 420A.
Type 440 battery (DBC 5995) can be identified by a white battery case.
CAUTION:
1990 M.Y. Sedans should only be equipped with the Type 440 battery.
Type 440 battery service procedures are as follows:
^ OPEN CIRCUIT VOLTAGE TEST (to determine battery state of charge):
CAUTION:
The battery must be at room temperature, 60-78~F (15-25~C) to achieve accurate test results.
1. If the battery has been charged or the engine run in the previous 24 hours, remove the surface charge by turning on the headlights for one minute, or as follows:
^ Connect the discharge tester to the battery following the equipment manufacturers instructions.
^ Apply 300 amps for 3 seconds.
2. Disconnect battery negative cable.
3. Wait five minutes after removing the surface charge. Measure the open circuit voltage by connecting the meter across the battery terminals, (Fig. 1).
4. Record the voltage to enable battery testing and evaluation. If the battery does not have to be removed for service, reconnect the negative cable and coat both terminals with petroleum jelly.
^ CHARGING (to bring a discharged but serviceable battery to a full charged condition):
1. Remove the vent cover(s) and ensure that the electrolyte level is 6 mm above the separators, (Fig. 2). Adjust the level with distilled water.
2. Slow charge the battery according to the equipment manufacturer's recommended time and procedure.
CAUTION:
Do not use a fast charger to charge battery.
3. After charging, adjust the electrolyte level to 6 mm above the separators (Fig. 2) with distilled water and install vent cover(s).
^ AFTER CHARGING CHECK (to determine if the recharge has brought the battery back to a fully charged condition):
1. Four hours after charging has been completed, test the open circuit voltage.
Open Circuit Voltage Action
12.70 V or more O.K. for service
12.20 - 12.69 V Step 2
12.19 V or less Replace battery
2. Recharge the battery at a slow rate according to the manufacturer's recommended time and procedure.
3. Check that the electrolyte level is 6 mm above the separators.
4. Four hours after recharging has been completed, retest the open circuit voltage.
Open Circuit Voltage Action
12.70 V or more O.K. for service
12.69 V or less Replace battery
^ IN SERVICE BATTERIES HIGH RATE DISCHARGE TEST (to ensure that the battery is serviceable and will not fail before the next scheduled maintenance interval):
1. Based on the results of the open circuit voltage that, one of the following test currents will be applied:
Open Circuit Voltage Test Current
12.60 V or more 180 A
12.45 - 12.59 V 130 A
12.20 - 12.44 85 A
12.19 V or less Charge and recheck
the open circuit
voltage before
testing
2. Connect the discharge tester to the battery following the equipment manufacturer's instructions and observe the battery voltage.
NOTE:
When using a Sun Vat 60 tester, switch to manual mode if voltage is 12.44 V or less.
3. Apply the appropriate test current (see table, step 1) to the battery for fifteen seconds, (Fig. 3). Observe the battery voltage at the 15 seconds and immediately reduce the current to zero.
Discharge Test Results Action
Minimum V or more O.K. for service
Less than minimum V Replace battery
CAUTION:
The minimum voltage will vary with the battery temperature.
Temp. (~F) Minimum Voltage
70 or more 9.6
60 9.5
50 9.4
40 9.3
30 9.1
20 8.9
10 8.7
0 8.5
4. Recharge the battery if the open circuit voltage was 12.59 V or less before discharge testing.
^ NEW BATTERIES HIGH RATE DISCHARGE TEST (to determine the serviceability of a new vehicle or a new in-stock battery):
1. With the battery negative cable disconnected, test the open circuit voltage of the battery. One of the following test currents will be applied:
Open Circuit Voltage Test Current
12.60 V or more 260 A
12.45 V - 12.59 V 210 A
12.20 - 12.44 V 110A
12.19 V or less Recharge and recheck
the battery before
testing
2. Connect the discharge tester to the battery following the equipment manufacturer's instructions and observe the battery voltage.
CAUTION:
The minimum voltage will vary with the battery temperature.
4. Recharge the battery if the open circuit voltage was 12.59 V or less before discharge testing.
^ DRY CHARGE ACTIVATION (this procedure ensures that new replacement batteries operate to their maximum serviceable performance):
1. Remove vent cover(s). Equally fill all battery cells to a level of 4-6 mm above the separators, (Fig. 5).
2. Test the electrolyte with a hydrometer (Fig. 6). It must have a specific gravity of 1.270 at 78~F (25~C). Refer to Fig. 7 for temperature correction.
3. Wait fifteen minutes after the initial refill. Add electrolyte to bring the level in each cell back to 4-6 mm above the separators, (Fig. 5).
4. Immediately after refilling the cells, charge battery at a slow rate according to the equipment manufacturer's recommended time and procedure.
CAUTION:
Do not use a fast charger to charge battery.
5. After charging, adjust the electrolyte level to 6 mm above the separators (Fig. 2) and install vent cover(s). Allow battery to stand for four hours.
CAUTION:
Ensure battery has stood for four hours before checking open circuit voltage.
6. Measure open circuit voltage of the battery.
Open Circuit Voltage Action
12.70 V or more O.K. for service
12.69 V or less Recharge and
check (next step)
7. If necessary, recharge the battery and adjust the electrolyte level to 6 mm above the separators. Install vent cover(s) and allow the battery to stand for four hours.
8. Measure battery open circuit voltage.
Open Circuit Voltage Action
12.70 V or more O.K. for service
12.69 V or less DO NOT PUT BATTERY
IN SERVICE