Battery Care and Maintenance/Power Supply
Battery: Battery Care And Maintenance/Power Supply
Model year: as of 2005
NOTE: This Technical Information replaces the following TIs:
Group 2:
- No. 1/04 - Battery care and maintenance prior to vehicle delivery
- No. 1/05 - Power supply while in the workshop and during diagnosis
Please mark the invalid TIs accordingly.
Vehicle Type:
911 Carrera (997)/911 Carrera S (997)/911 Carrera 4 (997) 911Turbo(997)
911 GT3(997)
Concerns:
- Battery discharge,
- Battery care and maintenance prior to vehicle delivery,
- Power supply for battery during...
- vehicle handover,
- time spent in the workshop,
- vehicle diagnosis,
- the time the vehicle is in the showroom.
Situation:
Summary of Technical Information releases published to-date.
This Technical Information contains a summary of and additional information on the previously published
Technical Information releases concerning the topics listed above.
This Technical Information is published in identical form in Group 0 (No. 1/06) and Group 2 (No. 1/06).
Contents:
The Technical Information is divided into the following three sections:
1 Battery care and maintenance prior to vehicle delivery
2 Power supply during vehicle handover to the customer
3 Power supply during time spent in the workshop, diagnosis and for showroom vehicles
1.Battery care and maintenance prior to vehicle delivery
Situation:
The following instructions are provided so as to achieve the optimum battery condition upon delivery to the customer.
Contents:
Overview of the topic "Battery care and maintenance prior to vehicle delivery":
1.1 Action required following vehicle delivery
1.1.1 Test and documentation times
1.1.2 Measurement and charging conditions
1.1.3 Documenting measured values
1.2 Checking battery condition and open-circuit voltage
1.2.1 Determining battery condition (= starting power)
1.2.2 Determining open-circuit voltage (battery disconnect switch fitted)
1.2.3 Determining open-circuit voltage (battery disconnect switch removed)
1.3 Recharging the battery
1.3.1 Procedure using the determined measurement result
1.4 Procedure prior to vehicle handover to the customer (sales check)
1.4.1 Checking battery in the course of the sales check
1.4.2 Concluding work
1.5 Details in the event of a complaint
Tools:
Multimeter, battery tester, charger.
Parts Info:
999.611.070.20 - Battery 70 Ah/340 A
999.611.080.20 - Battery 80 Ah/380 A
999.611.060.20 - Battery 60 Ah/280 A (GT3)
CAUTION: The battery cells may be permanently damaged (sulfated) if the battery charge state (open-circuit voltage) is less than 50 Percent (D 12.2 V).
- Check the battery condition and open-circuit voltage according to the following procedure.
Work Procedure:
1. Battery care and maintenance prior to vehicle delivery
1.1 Action required following vehicle delivery
Upon delivery of new vehicles, a Battery Maintenance Sheet (=> enclosure "Batt-Wart-Spw-06-en" for this Technical Information or => Battery Maintenance Sheet under "Standard forms" in the PIWIS Info system) must be issued for each vehicle.
The measured results for battery condition and open-circuit voltage tests must then be entered on the Maintenance Sheet.
1.1.1 Test and documentation times
- Upon vehicle delivery:
Initial test on battery condition (starting power, => 1.2.1) and open-circuit voltage (charge state, => 1.2.2).
NOTE: The battery disconnect switch must not be removed until 48 hours before handing the vehicle over to the customer; - 010000 Main switch for power supply (battery disconnect switch) (No. 1/04) and - 010100 Main switch for power supply: handling/removing/returning (Turbo and GT3, No. 2/06).
- Afterwards, the open-circuit voltage (charge state) and - depending on requirements - the battery condition (starting power) must be determined at the times specified below during each test:
- Every 7 days for demonstration or showroom vehicles.
- Every month if the main power supply switch is removed and the battery connected.
- Every 3 months if the main power supply switch (referred to here as the battery disconnect switch) is fitted or the battery is disconnected.
- Prior to vehicle delivery to the customer - during the sales check.
NOTE: While the vehicle is not in use, the acid level must be checked and corrected if necessary every 6 months, - 270601 Checking battery.
1.1.2 Measuring and charging conditions (temperature)
To ensure meaningful measurement results, the battery temperature must be > 32 degrees F (0 degree C). The temperature around the vehicle must be > 32 degrees F (0 degree C) for at least 12 hours.
If the temperature is below 32 degrees F (0 degree C), the battery or vehicle must be placed in the workshop (heated room) for at least 12 hours. This will ensure a uniform temperature within the battery.
The conditions mentioned above apply equally to charging the battery.
1.1.3 Documenting measured values
For the period from vehicle delivery to vehicle handover, - in addition to the ambient temperature
- the measured values for...
- battery condition (=> 1.2.1) and
- open-circuit voltage (=> 1.2.2 and 1.2.3) must be recorded in the Maintenance Sheet. The acid level must also be tested.
1.2 Checking battery condition and open-circuit voltage
1.2.1 Determining battery condition (= starting power)
- Battery condition test
The battery condition test must be performed using a battery tester.
The battery tester must be connected directly to the battery.
- Documentation and subsequent procedure
Enter the measured value in the Maintenance Sheet. Depending on the condition of the battery, proceed according to => 1.3.1.
1.2.2 Checking open-circuit voltage (= charge state)/battery disconnect switch fitted (L battery disconnected).
(Vehicle without battery disconnect switch => 1.2.3).
The open-circuit voltage is a measure of the charge state of the battery.
- Requirements
The open-circuit voltage can be measured immediately if...
- the vehicle has been parked for at least 2 hours with the battery disconnect switch open (= disconnect switch is pushed in as far as it will go in direction of travel) and
- the front luggage compartment lid is open and
- all the doors are closed and
- the battery disconnect switch is not actuated.
The open-circuit voltage can be measured after 2 hours at the earliest if...
- the battery disconnect switch was pulled as far as it will go to the "closed" position (e.g. to open the driver's door and/or to release the front luggage compartment lid) and
- is returned to the "open" position again after closing the driver's door.
If the disconnect switch is left in "closed" position at this stage, the open-circuit voltage can be measured after 2 hours and 15 minutes at the earliest.
- Measuring open-circuit voltage
On the positive and negative terminal of the battery.
- Documentation and subsequent procedure
Enter the measured values in the Maintenance Sheet. Depending on the open-circuit voltage value, proceed according to => 1.3.1.
1.2.3 Checking open-circuit voltage (= charge state)/battery disconnect switch removed and battery connected.
The open-circuit voltage is a measure of the charge state of the battery.
- Requirements
- Ignition key removed.
- Electr. loads switched off (e.g. parking light, interior light, etc.).
- All doors and rear luggage compartment lid closed.
- Lid lock on front luggage compartment pressed by hand to the "closed" position (e.g. using a screwdriver).
- Vehicle locked with the remote control.
CAUTION: The locked lid lock can become damaged if an attempt is made to press the lid into the lid lock, which was locked manually, after measuring the open-circuit voltage.
- Allow an inactive period of at least 2 hours before reading off the measured value on the multimeter and entering this in the Maintenance Sheet.
- Open the lid lock using the actuating button before closing the lid.
- Measuring open-circuit voltage
On the positive and negative terminal of the battery.
- Documentation and subsequent procedure
Enter the measured values in the Maintenance Sheet. Depending on the open-circuit voltage value, proceed according to => 1.3.1.
1.3 Recharging the battery
To charge the battery when connected, electronic chargers should be used which are compatible with the vehicle electrical system and charge according to "IU characteristics" (automatic charging, no risk of overcharging). See => 1.1.2.
When charging using other chargers:
The charging current must not exceed 1/10 of the nominal capacity of the battery to be charged, e.g. 8 A for an 80 Ah battery. The charging time or voltage must be monitored. The charger must be compatible with the vehicle electrical system. See => 1.1.2.
1.3.1 Procedure using the determined measurement result
- Starting power ≥ 100 Percent and charge state = 80 - 100 Percent (-12.5 - 12.7 volts)
The battery is OK.
- Starting power ≤ 100 Percent and charge state = 50-80 Percent (-12.2 - 12.5 volts)
Charge state is reduced, battery must be recharged once.
After charging the battery (=> 1.3) and following an inactive period of at least 2 hours, the open-circuit
voltage must be measured (=> 1.2.2 and 1.2.3).
- Starting power < 100 Percent and charge state = 10 - 50 Percent (D 11.6 - 12.2 volts)
Battery is discharged; battery must be recharged once.
After charging the battery (=> 1.3)...
- perform a battery condition test (=> 1.2.1),
- measure the open-circuit voltage after an inactive period of at least 2 hours (=> 1.2.2 and 1.2.3).
If the starting power and/or charge state is not 100 Percent or 12.7 volts after charging the battery, the battery must be replaced before handing the vehicle over to the customer.
- Starting power < 100 Percent and charge state less than 10 Percent (= less than 11.6 volts)
Battery is completely discharged.
The battery must be replaced before handing the vehicle over to the customer.
1.4 Procedure prior to vehicle handover to the customer
NOTE: The battery disconnect switch must not be removed until 48 hours before handing the vehicle over to the customer; - 010000 Main switch for power supply (battery disconnect switch) (No. 1/04) and - 010100 Main switch for power supply: handling/removing/returning (Turbo and GT3, No. 2/06).
1.4.1 Checking battery in the course of the sales check
Subsequent procedure is determined by the data documented in the Maintenance Sheet (e.g. check starting power, replace battery, etc.).
If the results of the previously completed battery tests were OK, the charge state must always be checked during the sales check; see below "-Checking open-circuit voltage (= charge state)". Subsequent procedure depends on the result obtained.
NOTE:
The battery must be replaced if...
- the battery was charged in the period up to the sales check and the starting power and/or charge state of the charged battery was < 100 Percent or < 12.7 volts, or
- the battery was totally discharged, or
- the battery is recharged during the sales check and afterwards the starting power and/or charge state are < 100 Percent.
- Checking open-circuit voltage (= charge state)
Determining the charge state (=> 1.2.2 and 1.2.3). It must be ≥ 100 Percent (≥ 12.7 volt open-circuit voltage).
If the charge state is OK:
Continue with => "Checking battery condition (= starting power)".
If the charge state ≤100 Percent (≤ 12.7 volts): Charge the battery (=> 1.3) and measure the open-circuit voltage (=> 1.2.2 and 1.2.3). If the charge state is then OK: Continue with => "Checking battery condition (= starting power)".
If the charge state is < 100 Percent (< 12.7 volts) after charging the battery: replace the battery.
- Checking battery condition (= starting power)
The battery condition test (=> 1.2.1) is only necessary if the battery was recharged between vehicle delivery and prior to the sales check because...
- when the vehicle was delivered, the starting power was < 100 Percent or in the period up to the sales check, the charge state was < 50 Percent (< 12.2 volt open-circuit voltage).
If the starting power is < 100 Percent: replace the battery.
- Documentation
The measurement results during the sales check and the vehicle handover date must be recorded on the Maintenance Sheet.
File the completed Maintenance Sheet with the sales documents for the vehicle.
1.4.2 Concluding work
After connecting the battery, the following work, for example, must be performed before starting to drive the vehicle.
Initializing the steering-angle sensor
The steering-angle sensor must be re-initialized. To do this, move the steering at least 20 degrees in a single movement both to the left and right with the engine running.
Then drive the vehicle in a straight line until the PSM warning light goes out. The steering-angle sensor segment is recognized again in this process.
Tire Pressure Monitoring
After completing the required work, drive the vehicle until the tire pressure values are displayed in the instrument cluster.
Teaching power windows
With the vehicle doors closed, teach each of the power windows as follows:
- Actuate the rocker switch to "Close" and fully close the window once.
- Actuate the rocker switch to "Close" again. The upper end position is now stored.
- Actuate the rocker switch to "Open" and fully lower the window once.
- Actuate the rocker switch to "Open" again. The lower end position is now stored.
1.5 Details in the event of a complaint (after vehicle delivery)
Following vehicle delivery, information regarding the operating condition of the battery when it failed in the vehicle and details of the complaint must be stored.
Information on the following points must be recorded under "Comments" on the Battery Maintenance Sheet:
- Short (< 6 miles/10 km)/long-distance operation?
- Idle times (seasonal vehicle use)?
- Was a Porsche approved battery maintainer used?
- Vehicle in original condition?
NOTE:
When a battery is replaced in the event of a complaint, the relevant battery condition and open-circuit voltage values of the battery to be replaced must be entered on the Battery Maintenance Sheet.
The completed Maintenance Sheet must be filed.
We reserve the right to reject warranty claims if these care and maintenance instructions are not observed. These
Battery Maintenance Sheets will be reviewed as required as part of the PSA (Porsche Service Analysis).
References:
- 010000 Main switch for power supply (battery disconnect switch) (No. 1/04)
- 010000 Return of main switches for power supply (No. 2/04)
- 010100 Main switch for power supply: handling/removing/returning (Turbo and GT3, No. 2/06)
- 2706IN Work instructions after disconnecting the battery - 270601 Checking battery
Chapter 3 Workshop equipment: Battery Rapid-Start Charger "Bosch BSL 2470"
Enclosure:
Battery Maintenance Sheet "Batt-Wart-Spw-06-en"
In PIWIS Info system: => 'Standard forms' => 'Battery Maintenance Sheet'
2. Power supply during vehicle handover to the customer
NOTE: Please pass on this information to your Sales department as well.
Situation:
In the course of vehicle handover to the customer, numerous electrical loads are activated when demonstrating the vehicle.
Since most of the demonstration takes place with the engine switched off, battery usage is very high during this time.
To maintain optimum battery condition during vehicle handover, a battery charger must be connected during vehicle demonstrations.
Please read the following information as well as "Vehicle Handover Guide for Boxster and Carrera" in the "Porsche Academy" online training platform.
Contents:
Overview of the topic "Power supply during vehicle handover"
2.1 Using a battery charger
2.2 Connecting a battery charger
Tools:
Battery charger (at least 40 A)
Work Procedure:
2 Power supply during vehicle handover
2.1 Using a battery charger
Make sure that the battery was charged prior to vehicle handover and that the charge state is 100 Percent (5= 12.7 volts) and the starting power is 100 Percent (=> 1.2).
To maintain the charge state of the battery, connect a suitable charger to the vehicle electrical system before starting vehicle handover.
NOTE: Porsche recommends the battery charger with the tradename "BSL 2470" from Bosch.
If you are using a battery charger from another manufacturer, it should have an output of at least 40 A and must be compatible with the vehicle electrical system.
Observe the manufacturer's instructions for adjusting and operating the battery charger.
2.2 Connecting the battery charger
The charger must be connected to the battery terminals before starting vehicle handover, - 270601 Battery trickle charge.
References:
- 270601 Battery trickle charge
- Battery
3. Power supply during time spent in the workshop, diagnosis and for showroom vehicles
Situation:
To maintain the charge state during time spent in the workshop, during diagnosis and for showroom vehicles, a battery charger must be connected to the vehicle electrical system.
Contents:
Overview of the topic "Power supply during time spent in the workshop, diagnosis and for showroom vehicles":
3.1 Power supply...
- during time spent in the workshop (working on the vehicle),
- during diagnosis and/or control unit programming
3.2 Power supply for showroom vehicles
Tools:
Battery charger (30 A or 40 A)
Work Procedure:
3. Power supply during time spent in the workshop, diagnosis and for showroom vehicles
3.1 Power supply...
- during time spent in the workshop (working on the vehicle),
- during diagnosis and/or control unit programming.
A charger must always be connected when carrying out the following work:
- Working on the vehicle
Work that takes more than 15 minutes and for which the battery is used via the vehicle electrical system, e.g. when...
- the ignition is switched on (terminal 15),
- doors and/or lids are open,
- the Infotainment system is used,
- setting/checking the lighting system,
- other electrical loads are switched on, and so on.
One of the reasons for this is the data exchange between the control units via the "CAN bus" and the resultant increase in power usage by the control units in the vehicle.
- Diagnosis and control unit programming
The reason for this is the increased power usage, which can cause a voltage drop. If a charger is not connected, the resultant undervoltage can result in one or more fault entries in the control unit and can cause the abnormal termination of control unit programming.
NOTE: Porsche recommends the battery charger with the tradename "BSL 2470" from Bosch.
If you are using a battery charger from another manufacturer, it should have an output of at least 40 A and must be compatible with the vehicle electrical system.
Observe the manufacturer's instructions for adjusting and operating the battery charger.
NOTE: To prevent incorrect readings when measuring power and voltage using the PIWIS Tester or other test or measuring instruments (e.g. oscilloscope), the charger must be disconnected from the vehicle battery for the duration of the measurements.
3.1.1 Connecting the battery charger
The charger must be connected to the battery terminals before starting work.
3.2 Power supply for showroom vehicles
CAUTION:: While off the road, demonstration and exhibition vehicles are subjected to a higher battery load due to electrical loads being switched on with the engine off.
- Showroom vehicles must be connected to a battery charger (see also => After Sales News No. 10/2002).
- Trickle chargers, such as "Charge-O-Mat", are not suitable.
NOTE:
Porsche recommends the battery charger with the trade name "CG32" from Gossen for showroom vehicles.
If you are using a battery charger from another manufacturer, it should have an output of 30 A and must be compatible with the vehicle electrical system.
Observe the manufacturer's instructions for adjusting and operating the battery charger.
3.2.1 Connecting the battery charger
The charger must be connected to the battery terminals after you have parked the vehicle in the showroom, - 270601 Battery trickle charge.