Table of contents: Visual examination ↓ Checking the hydrometer ↓ Checking the wires ↓ Checking connections and electrical…↓ Load test ↓
Visual examination
Check for obvious damage such as cracking or breaking of the case or cover that could result in electrolyte leakage. If obvious damage is found, replace the battery. Identify the cause of the damage and eliminate it if necessary. If visual inspection reveals no damage, continue with further diagnostics.
Checking the hydrometer
The indicator is green, you can continue the diagnostics further. The indicator is black - charge the battery.
Checking the wires
Battery cables can deteriorate over time. Signs of cracks or corrosion may not be obvious, but the wire still needs to be replaced. Feel the wire. It should be flexible and not hardened. Lightly trim the insulation near the ends and check the conductors. If there are signs of corrosion, replace the wire(s).
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Caution: It is recommended to replace battery cables in pairs because their condition will be approximately the same.
Checking connections and electrical grounding
Electrical grounds such as from the battery to the engine block and from the engine block to the body are not generally considered sources of faults. Check all connections. They must be clean on all contact surfaces and tightly tightened. Make sure there are ground straps from the engine to the body and/or chassis.
Whenever the battery, cables and connections are repaired, inspected, replaced or cleaned, lubricate the connections with a thin layer of petroleum jelly to protect against corrosion.
Check connections on all sensors, actuators and other devices. They must be connected correctly and tightened tightly.
Load test
Load testing may require the use of adapters to the battery terminals to ensure good contact.
Connect a voltmeter and a battery tester to the battery terminals.
Apply a 300A load for 15 seconds to remove surface charge from the battery. Take the load off.
After the 15 second break required to allow the battery to recover, apply the load specified in the battery documentation. After 15 seconds, record the tension and then remove the load.
If the voltage does not drop below the minimum value, the battery is in good condition and can be used further. If the voltage drops below the minimum level, the battery should be replaced (the battery temperature should be determined by touch, taking into account the temperature at which the battery was located during the previous several hours).
| Estimated temperature,°C | Minimum voltage, V |
| 21 | 9,6 |
| 20 | 9,4 |
| 0 | 9,1 |
| -10 | 8,8 |
| -18 | 8,5 |
| below -18 | 8,0 |