IK0800482 Service Bulletin/Repair Instructions

IK0800482 ­ Battery Testing, Diagnostics, and Maintenance information
Countries:
Page 1 of 4
BAHAMAS, BOLIVIA, BELIZE,

CANADA, CHILE, TAIWAN,

COLOMBIA, COSTA RICA,

DOMINICAN REPUBLIC, ECUADOR,

EL SALVADOR, TRINIDAD AND

Document

TOBAGO, UNITED STATES,

IK0800482

URUGUAY, VENEZUELA, MEXICO, ID:

ARUBA, NICARAGUA, PERU,

Curaçao, GUAM, GUATEMALA,

GUYANA, HAITI, HONDURAS,

JAMAICA, KOREA, SOUTH KOREA,

PANAMA
Availability:

Major

System:

Current

Language:

Other

Languages:
ISIS, Bus ISIS, FleetISIS, NotSIR
Revision: 11
ELECTRICAL SYSTEM
Created:
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Last

10/31/2016

Modified:
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Title : Battery Testing, Diagnostics, and Maintenance information

Applies To : All Vehicles
CHANGE LOG

10/31/2016 - Updated Odyssey warranty process.

08/02/2016 - Updated battery charge time table

05/10/2016 - Added Enersys/Odyssey Warranty Information.

04/01/2016 - Author addressed feedback

02/19/2016 Added further clarification about submitting for 55 OTC parts warranty in Red Font at top of page in description



DESCRIPTION

This document covers battery diagnostics, maintenance, and storage requirements. Failure to follow the

instructions can result in a false indication of a failed battery(s).

Note : If battery is being tested under 55(Parts over the counter warranty), when prompted on the battery tester “Is

this a Navistar Vehicle”, select ‘YES’

Note : If vehicle is equipped with Odyssey Batteries please file warranty through Navistar.
SYMPTOMS

The vehicle may have one or more of the following symptoms:
•

•

•

•
No start

Hard to start

Low voltage on gauge

Repeated jump starts
SPECIAL TOOLS
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IK0800482 ­ Battery Testing, Diagnostics, and Maintenance information
Tool Description
Tool Number
MidTronics inTellect EXP battery and

electrical diagnostic tester
n/a
Page 2 of 4
Comments
Instructions
DIAGNOSTIC STEPS

Step Action
Decision
Pre-Test Inspection

1. Inspect for loose connections at the battery and connected components (Starter,

Alternator, Ground, etc...)

1
Go to Step 2

2. Remove any corrosion with battery cleaning spray, or baking soda/water paste. Then rinse

clean.

Have all connections been found tight, and without corrosion?
Step Action
Decision
Battery Pack Breakdown Test

Good Battery(s) : Battery

Diagnostics complete.
1. Do the "Test Preparation" as described in Section 4 of the Midtronics EXP

Instruction Manual.

2. Select "System Test" and follow procedure for testing battery individual battery, as

described in Section 5 of the Midtronics EXP Instruction Manual

2
Note : Do not test as a pack. Test batteries individually.
Replace/Bad Cell : Go to

Step 3
Note : Use Midtronics battery stud adaptors and tighten properly on each battery

tested. Failure to do so will yield inaccurate results.

Note : Keep all generated MidTronics codes during testing to later be submitted

on Warranty Claim (If 01,03,39, or 55 warranty applies)
Charge and Retest : Charge

batteries to a minimum 75%

(12.6V), and reperform Step

2
What were the individual test results for each Battery?

Step Action

3
Battery Replacement

1. Replace only the batteries that the tester has failed.

2. The technician must ensure that the open circuit voltage of the new
Decision

Yes : Continue to Starter

diagnostics located at

IK0800407 (For ISB applications

go to : IK0800503 )

No : Release the Vehicle
battery is near the voltage of the remaining batteries in the pack, to

avoid arcing and overheating of the terminals as the new battery is being

installed.

Note : Replace bad batteries with the same part number as the remaining

good batteriesNote : Do not mix battery types. AGM, flooded, or hybrid must

be matched with the same..

Note : Do not mix CCA (Cold Cranking Amp) or RC (Reserve Capacity)

ratings.

Note : For sleeper applications, do not use flooded batteries. Use only AGM

or other Navistar approved parts.
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IK0800482 ­ Battery Testing, Diagnostics, and Maintenance information
Page 3 of 4
Note : For sleeper applications, do not use flooded batteries. Use only AGM, or other

Navistar approved parts

Is No/Slow cranking concern still present?
WARRANTY INFORMATION

Warranty Claim Coding:

Group:
08550
Nouns:
710, 712
Standard Repair Time(s):
Step

1-2

3
Description
SRT Link
Hours
Battery Test
A08­2710A
SRT Time
Battery Replacement
Model Dependent
SRT Time
Special Requirements

Dealers: For each battery filed under warranty (01,03,39,55 Over the counter, and service part), test result codes generated by

the Midtronics tester must be printed out, and attached to the claim, or scanned and added as an attachment. Refer to CTS1100, and WPL2800114.

Fleets: Refer to fleet battery warranty policy.
APPENDIX

MAINTAINING BATTERIES DURING VEHICLE STORAGE

Truck and Bus batteries must be maintained during vehicle storage or battery deterioration, or possible failure can

result. Battery life will be shortened if the batteries are not kept properly charged while in storage.

If batteries fail while the vehicle is in storage, or on the lot will not be considered for reimbursement or warranty.

The Dealer is responsible for adequate storage and protection of new vehicles, whether they are on Dealer premises or elsewhere.

Correct any conditions creating unnecessary expense and/or preventable customer dissatisfaction. When vehicles are delivered

directly to a TEM / body manufacturer, the Dealer should arrange for proper vehicle storage and maintenance. We recommend

sending a copy of these procedures to the body manufacturer.

The complete Navistar Vehicle Storage policy is explained in the Warranty Policy Manual CTS1100, and WPL2800091
Battery/ Battery Pack Charging Chart

Note : This chart is only to be used as a guideline illustrating approximate charge times for certain

battery/battery pack conditions.

When a battery or batteries need to be charged the following procedures needs to be followed.

The Midtonics Smart Charger PSC550CC is the recommended equipment for charging batteries.

This type of charger will charge the battery or batteries to insure proper and safe charging without

overcharging.
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IK0800482 ­ Battery Testing, Diagnostics, and Maintenance information
Page 4 of 4
If a smart charger is not available, a regular charger can be used. Follow the table below as a guide on

how long it takes to charge each battery.

NOTE: The charge rates are for one battery. For additional batteries take each time and multiply it by the

number of batteries in the pack.
Odyssey Battery Distributor / Specialist WARRANTY CLAIM

PROCEDURE

This procedure provides the process that is to be followed to perform an ODYSSEY® battery warranty claim by

any authorized ODYSSEY Distributors. Per the ODYSSEY® Battery General Product Limited Warranty, warranty

service can be provided by any authorized ODYSSEY battery distributor, wholesaler, or dealer provided it is

determined that failure is due to defective material or workmanship under the terms of the ODYSSEY Battery

Product Warranty. Warranty Validation Procedure and Warranty Portal instructions included in this document.

1. ODYSSEY Distributors / Specialists will perform the “ODYSSEY Product Warranty Validation Procedure” for

batteries that are at least 10.0V OCV and have failed within the warranty period based on battery model and

application use according to the most current ODYSSEY® Battery General Product Limited Warranty can be

warranted.

2. Defective batteries that are unrecoverable and meet the ODYSSEY® Battery General Product Limited

Warranty and warranty validation procedure requirements are warrantable and claims should be submitted via the

EnerSys Warranty Claim Portal for ODYSSEY® batteries. A claim number will be assigned to the claim for the

submitter reference. Note that the 14 digit Serial Number from both the warranty claim battery and the

replacement battery will be required to submit the warranty claim.

3. Upon receipt of warranty claim request and approval by EnerSys Customer Service via the warranty claim

portal a stock replacement battery will be shipped to the ODYSSEY dealer location that submitted the claim.

Contact your EnerSys Customer Service Representative or EnerSys Warranty Portal Support at 888­422­0317 or

[email protected] for warranty deviation inquiries, approvals for alternate testing, or consideration of other

non­standard potential warranty

issues.

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Copyright © 2016 Navistar, Inc.
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