TSB 311-2145: Electrical - Battery Maintenance

Details

Bulletin Number: 311-2145 Date: May, 1999 Market: SE Maintenance program for starting battery Cars affected 9-3, 9-3CV and 9-5 from M1999. Background This SI replaces SI 311-1773, SI 100-1482 as well as the sections concerning battery maintenance in Service Manual 1 Service and 3.1 Electrical system. If a battery is left without maintenance for long periods, its charge level will successively drop. What principally determines the speed of the drop is the size of the current being consumed by the car's electrical system. Even if the battery is disconnected, a certain discharge will take place. This will increase with temperature. If the battery is left standing at a low charge level for long periods, a chemical process will be initiated in which the battery acid gradually converts to water and the battery plates start to corrode. This corrosion process will start to be critical if the battery is left standing for about 2 weeks at a charge level below 65-75 % (corresponding to a battery voltage less than 12.4 volts without a load). A battery with low charge level can freeze even at 0°C, which will also damage the battery plates. The damage this causes is permanent and can not be remedied by charging the battery in the normal way. This means that the deterioration in the battery's capacity and service life is permanent. The objective with this maintenance program is to prevent this kind of damage to the battery from ever occurring and therefore increase the service life of the battery, and above all to ensure that the customer always receives a battery that is in good condition. Parts required Brief summary of the battery maintenance program This program is a procedure to document the battery's condition from factory to end-user. Each car is issued with a battery card at the factory. The battery is checked during the delivery approval and the results registered on the battery card. The battery is tested with a new type of battery analyzer, which, besides measuring the voltage, is able to measure and assess the battery's current capacity. A similar analyzer (Battery Analyzer 311) is to be available at each dealership. This analyzer provides test results in writing and a test code that contains all the test values. When the car is standing in storage at the dealership and the battery is not disconnected, the battery must be checked monthly and the result entered onto the battery card. Demonstration cars (in showrooms, etc.) are checked weekly if the battery has not been disconnected. Battery Analyzer 311 will indicate whether the battery is in need of recharging. After charging, the battery card is updated with a new test. When the car is delivered to the customer (pre-delivery service), the battery status in the form of a test code together with the mileage and the date is entered into the customer's "Saab Service" book. The test code from Battery Analyzer 311 must accompany warranty claims if the claim is to be approved. Battery Analyzer 311 Battery Analyzer 311 is manufactured by Midtronics Inc. in the USA and uses a patented measuring method (conductance), which is able to measure not only the battery voltage but also the battery's current capacity. Saab Automobile AB judges this analyzer to be the most suitable test instrument on the market for this kind of maintenance program. Using this analyzer makes it possible to obtain a uniform battery test method on all Saab's markets around the world. Handling is simple as there are only four buttons to use: ^ two arrow buttons for making selections in menus ^ Gone <-- button to confirm selections ^ Gone "i" button to read the test code A special Saab adapted test program enable the analyzer to provide test results in writing as well as in the form of an 8-character test code. The analyzer does not require a separate power source as it is supplied by the battery to which it is connected during the test. Only 12 V starting batteries can be tested. The analyzer can also be used to check batteries from Saab 900 and 9000. Saab Automobile AB offers a one year warranty on the analyzer. During the warranty period, a defective instrument can be reclaimed to Parts Testing, Saab Automobile AB, Trollhattan. A new analyzer can be ordered through normal spare parts procedures. Important Test cables must never be repaired or replaced with others as the instrument and its test cables have been calibrated as one unit. If test cables from another battery analyzer are used, for example, incorrect test values will be obtained. For repair of test cables or instrument, both items must be sent in together. Battery card The objective of the battery card is to chart and document the condition of the battery from the factory to the end-user. The car's VIN is entered onto the card and the card placed in the glove compartment when the car leaves the assembly line. The first test is registered on the card when the car is delivery approved at the factory and the card then accompanies the car all the way to the final dealer. The battery card is of no use once the car has been delivered to the customer. The battery card must be updated as described below. The numbers refer to the respective zone on the battery card, see illustration. 1. Vehicle (Dealer Reference No) Used by the dealer as necessary (stock no., coordinate, etc.) to help identify and locate the car and respective key . 2. VIN The car's vehicle identification number as specified at the factory. Factory This section is completed at the factory after the battery has been approved for delivery. 3. Battery OK Date The date the battery was checked and approved for delivery at the factory (Customer Care). 4. Code Battery test code according to battery test at factory. 5. Battery type - CCA (SAE) The marked box specifies the size of the factory-fitted battery in CCA ("Cold Cranking Amps") according to SAE standard. Dealer The result of every battery test carried out while the dealer is responsible for battery maintenance, i.e. up until the day the car is delivered to the customer is registered in this section. 12 Date The date the battery is checked is noted here. Normally, the battery is checked monthly. Demonstration cars in showrooms, etc., are tested weekly. This applies if the battery has not been disconnected. 13 Code The test code obtained from Battery Analyzer 311 is noted here. Note The test code is required for possible warranty claims on the battery. 14 Message - Action The test message given by Battery Analyzer 311 is noted here together with any measures taken where appropriate. Note If charging is needed - Check the battery and update the battery card after charging. Monitoring system Besides Battery Analyzer 311 and the battery card, each dealer should have a system for keeping track of cars requiring test or recharging respectively. We recommend a simple PC register program or a binder system where cars in storage, showroom cars and cars being made ready for delivery can be identified. Test procedure Select the relevant alternative in each menu with the arrow buttons. Use the <-- button to confirm a selection. The selections that are made now will remain as default selections the next time the analyzer is turned on. 1. Check the acid level in the battery and top up if necessary (especially on warm markets). If the battery has been used for a time with low acid level, it should be charged after topping up before the battery test is carried out. Note Low battery acid level for a long period will cause permanent damage to the battery and shorten its service life. 2. Clean the battery terminals. 3. Connect the red cable clamp to the positive terminal (+). (Incorrect polarity will not harm the analyzer.) 4. Connect the black cable clamp to the negative terminal (-). Once both clamps are connected, the analyzer will be activated automatically and initiate a self-test. In case of a fault in the analyzer, the message "INTERNAL FAULT SERV. REQUIRED" will be displayed. 5. Make sure the cable clamps make as good contact as possible. Note The test can also be conducted while the battery is connected to the car's electrical system. The ignition key must then be removed. If the analyzer registers disturbance from the car's electrical system, the message "SYSTEM NOISE" will be displayed continuously until the source of disturbance has been removed. If the DICE/ICE control module (applies to 900, 9-3 and 9-5) was active at the time, maxi fuse 2 in the maxi fuse board must be removed. See further under "Fault - diagnosis". 6. At "SELECT TEST", select whether the battery is connected to the car's electrical system ("IN-VEHICLE") or not ("OUT-OF-VEHICLE"). 7. At "BATTERY TYPE", select whether the battery is factory-fitted ("SAAB BATTERY") or a replacement battery of another make ("NON SAAB"). 8. Confirm "SELECT TEST BY SAE(A)" if the battery's cold starting current is specified to CCA (SAE) standard. For batteries specified to DIN standard, select and confirm "SELECT TEST BY DIN (A)". Note CCA (SAE) always applies to Saab factory-fitted batteries DIN standard can be selected when the analyzer is used to check replacement batteries that are not specified to SAE standard. 9. Enter the battery's rated cold starting current. On Saab factory-fitted batteries, this value can be found with large text on the label on top of the battery from model year 1999. The table shown specifies the CCA (SAE) values for factory-fitted batteries from model year 1994 and onwards that should be used when testing the relevant battery with Battery Analyzer 311. Note If the battery's cold starting current can not be identified, the following standard values can be used. Once the value has been selected and confirmed, the actual battery test will start automatically. The analyzer may then require further information before the result can be presented. A. "BATTERY TEMP" Under certain circumstances, the analyzer may need to know whether the temperature of the battery is above or below 0° (32°F) in order to make a correct assessment of the battery. This can happen even if the battery is tested at room temperature. By selecting and confirming the correct value, a new test will be started. B. "SURFACE CHARGE DETECTED" Under certain circumstances, the charge may be present only on the surface of the battery plates. This provides a relatively high voltage reading but does not contain any practical starting energy. In order to obtain a correct assessment of the battery in this case, the analyzer will request that the operator turn the ignition key to ON and turn on the headlights for a few seconds by displaying the message "TURN KEY ON HEADLAMPS ON". The analyzer then indicates when the load should be disconnected with "IGNITION OFF HEADLAMPS OFF". A new battery test will start automatically when this has been done. If the analyzer does not detect that the load has been connected or disconnected the message "WARNING" will first be displayed, followed by "LOAD ON NOT DETECTED" or "LOAD OFF NOT DETECTED'1 respectively. C. "SELECT MODE BEFORE CHARGE" "SELECT MODE AFTER CHARGE" Under certain voltage and conductance conditions, the analyzer will need to know whether the test is being carried out before or after the battery has been charged in order to make a correct assessment of the battery. Note Make a practice of checking the battery acid level before testing the battery. This is especially important in warm climates. After answering the question/s, the analyzer will display the results in one of the ways shown. When the messages "GOOD BATTERY" and "GOOD - RECHARGE" are shown, the display will alternate between displaying the message and showing the degree of charge in steps of 250/0, e.g. "STATE OF CHARGE: 0-25%". This value gives a clear indication of the current state of the battery. When the analyzer indicates that the battery should be replaced under warranty, we recommend performing an extra test with the battery out of the car. The test code from this test should be attached to the warranty claim (see further under Warranty Policy). Note Check a replacement battery with Battery Analyzer 311 as well before fitting it in the car. If the cold starting current of the replacement battery is not specified to SAE standard, select the DIN standard test in step 7 above. Fault diagnosis 1. If the display does not come on: ^ Check connections to the battery and that polarity is correct. ^ If the battery voltage is below 5.5 volts, the battery analyzer will not start. Charge the battery and test again. 2. If the message "CHECK CONNECTION" is displayed: Check that both halves of each connecting clamp have good contact with the respective battery terminal. 3. If the test message "SYSTEM NOISE CHECK LOADS" is displayed: This message may occur when testing a car in which the analyzer has detected some kind of disturbance from the car's electrical system that may affect the test result. In the 9-3/9-5, this message will occur mainly when the DICE control module is active. The DICE control module has a run-on time of 20 minutes after the ignition has been turned off and is activated when a door is opened. The DICE control module can be de-energized by removing maxi fuse 2 from the maxi fuse board. Maxi fuse 2 is always the second fuse from the +30 cable terminal screw. The maxi fuse holder in the 9-3 is located by the battery. The maxi fuse board in the 9-5 is located behind the engine bay fuse box. If the TWICE control module is in transport mode (9-3/9-5 only), the door can be opened without activating the DICE control module. If the "SYSTEM NOISE" message persists after several test attempts - disconnect the negative battery cable and perform a new test. In this case, the standing current should also be measured as the fault symptom indicates that an electric consumer is still active. Note The same test message can be obtained when testing Saab 900 batteries and then mainly when the ICE control module is active. The ICE control module has a run-on time of 20 minutes after the ignition has been turned off and is activated when a door is opened. By removing maxi fuse 2 in the maxi fuse board, the ICE control module can be de-energized. Test code The Saab battery test code can be read at any time by pressing the button. The test code consists of 8 characters and contains all the information from the battery test in coded form and is required for all warranty claims. The code is interpreted during warranty and quality reviewing by special software. This test code (together with the VIN and test date) will also be used to track the condition of the battery from the factory to the end-user and determine how the distribution chain can be optimized in the future. Press the "i" button once more to return to reading the test results. Note The test code can only be obtained when the "SAAB BATTERY" test type has been selected. Otherwise, the message "NON SAAB BATTERY TEST". Note For continuous trickle charging of batteries in demonstration cars, an especially adapted charger will lower voltage should be used. Too high a voltage from the charger will damage the battery due to overcharging. Charging code At any time during the reading of test results, the button can be pressed to display a charging code. This code is for future use and will then be entered into an especially intelligent battery charger for automatic and adapted battery charging. Charging Warning Never recharge a deeply discharged battery that has been standing in the cold as the battery acid will then consist mostly of water and may have frozen. Charging a frozen battery without prior thawing may crack the battery casing. The battery must be charged if the battery analyzer displays any of the following test messages: "GOOD - RECHARGE" "CHARGE & RETEST" A battery charger with charging current approx. 10-20 % of the battery's rated capacity, i.e. 7-14 amperes for a 70 Ah battery, should be used. Normal charging time is 4