DSG-423 CHARGING SYSTEM
06-7
Battery Drain Test
WARNING: REFER TO CAUTIONS & WARNINGS AT
THE BEGINNING OF THIS SECTION.
A defective component or wiring defect may be causing
a small current drain that is less than the fuse rating for
the circuit so the fuse does not open. Perform the
following to determine if an excessive drain is occurring:
NOTE: Batteries should be fully charged for the
following test.
WARNING: DO NOT ATTEMPT THIS TEST ON A
LEAD-ACID BATTERY THAT HAS RECENTLY BEEN
RECHARGED. EXPLOSIVE GASES MAY CAUSE
PERSONAL INJURY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
CAUTION: To prevent damage to the meter, do not
crank engine or operate accessories that draw more
than 10A.
1. Allow the engine to sit with the ignition off for at least
40 minutes to allow the GCP to power down.
2. Connect a fused (10A) jumper wire between the
negative battery cable and post to prevent the GCP
from resetting and to catch capacitive drains.
3. Disconnect the negative battery cable without
breaking the connection of the jumper wire.
NOTE: It is very important that continuity between the
negative battery cable and post is not broken. If it is, the
entire procedure must be repeated so the GCP can
power down again.
4. Connect an ammeter between the negative battery
cable and post. The meter should have a 10 amp
capability.
NOTE: If after this next step, the meter settings need to
be switched or the test leads need to be moved to
another jack, the jumper wire must be reinstalled to
avoid breaking continuity.
5. Remove the jumper wire and note the amperage
draw:
• There should not be any more than 50 mA (0.050
amp) draw.
• If excessive, remove fuses one at a time until the
circuit with the excessive draw is located.
• Use the wiring diagram to locate any circuits that
do not pass through the fuse box.
• Disconnect the generator connections to check
for an internal short causing an excessive draw.
Battery Load Test
WARNING: REFER TO CAUTIONS & WARNINGS AT
THE BEGINNING OF THIS SECTION.
1. Disconnect both battery terminal cables. Check the
battery visually.
2. Examine the hydrometer eye (if no eye go to next
step).
• Eye shows green - go to step 4.
• Eye shows dark - recharge, then go to step 4.
• Eye shows yellow - replace battery.
3. Apply a 300 amp load for 15 seconds. Turn off load
and wait one minute.
• If 12.4 volts or more - go to step 4.
• If less than 12.4 volts - recharge, then repeat step
3.
4. Apply a test load equal to 50% of the battery CCA
rating at - 17.8° C (0°F). After 15 seconds, with the
load still applied, measure and record terminal
voltage ___________. Turn the load OFF.
5. Estimate the battery temperature. If measured
voltage does not meet or exceed the value shown in
the following table, replace the battery.
6. Clean all cable ends and terminals of the battery with
a wire brush.
Temp. °C 21.1° 10° -1.1° -9.4° -17.8°
Temp. °F 70° 50° 30° 15° 0°
Min. Volts 9.6 9.4 9.1 8.8 8.5
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