IK0800482 ­ Battery Testing, Diagnostics, and Maintenance information

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Document
TOBAGO, UNITED STATES,
IK0800482
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Revision: 11

ELECTRICAL SYSTEM

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10/31/2016
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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

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

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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