The FJC Carbon Pile Battery Tester, Part #45115, is a diagnostic tool designed for testing 12V lead-acid batteries, alternators, and regulators. It provides essential information about a battery's state of charge, its ability to hold a load, and the performance of the vehicle's charging system.

Function Description:

The primary function of the FJC Carbon Pile Battery Tester is to assess the health and performance of 12V lead-acid batteries and associated charging components. It achieves this by applying a controlled load to the battery and measuring its voltage and current response.

Battery State of Charge Test: This test determines if a battery has sufficient voltage to be load tested. It involves connecting the tester to the battery, applying a brief 100-amp load, and then reading the voltmeter. If the voltmeter pointer falls within the "green zone" on the 'STATE OF CHARGE' scale, the battery is adequately charged for a load test. If it's to the left of the green zone, the battery voltage is too low, requiring a charge before further testing. A battery that still reads low after charging is considered defective.
Battery Load Test: This is a crucial test that simulates the demands placed on a battery during vehicle starting. The tester applies a load equivalent to one-half (1/2) of the battery's Cold Cranking Amperage (CCA) rating for 15 seconds. During this period, the tester monitors the battery's voltage. A built-in alarm sounds after 15 seconds to indicate test completion. The voltage reading at the end of the test, in conjunction with a "Battery Load Test Temperature Compensation Chart" (located on the side of the tester), determines if the battery is good or defective. For instance, at 60 degrees Fahrenheit, a voltage reading above 9.6 volts indicates a good battery, while below 9.6 volts suggests a defective one. The manual explicitly warns that if smoke is emitted from any cell during this test, the battery is defective regardless of other results.
Alternator and Regulator Charging Test: This test assesses the vehicle's charging system. After ensuring the battery itself is in good condition, the tester is connected to the battery terminals while the vehicle engine is running. The voltmeter pointer should ideally be in the green zone. If it falls into the red zone, it indicates that the alternator is not producing adequate voltage to charge the battery, suggesting a potential issue with the alternator or regulator.

Important Technical Specifications:

Compatibility: Tests 12V batteries, alternators, and regulators.
Load Capacity: Capable of applying a significant load, up to 500 amps, as indicated by the "500AMP CARBON PILE LOAD TESTER" label on the device.
Measurement: Features both a DC Amps meter and a DC Volts meter for precise readings.
Adjustability: Equipped with a Load Control Knob to adjust the applied load and adjusting screws on the meter faces to zero the pointers before testing.
Safety Features: Includes an audible alarm for the 15-second load test duration.

Usage Features:

Pre-Test Preparation: Emphasizes critical safety steps before testing, including ensuring a well-ventilated area, checking battery fluid levels, ensuring cell caps are in place, and cleaning battery terminals. It also warns against testing frozen batteries or those with loose terminals or cracks.
Connection Precautions: Instructs users to ensure the Load Control Knob is in the "off" (counter-clockwise) position before connecting the clamps to the battery terminals, and to ensure a good connection.
Moisture Removal: Provides a procedure for removing moisture from the carbon pile if steam is observed during testing, involving applying a 100-amp load for 10 seconds.
Multiple Tests: Advises allowing sufficient cooling time (up to 10 minutes) between multiple tests on different batteries to prevent damage to the tester and extend its lifespan due to the significant heat generated during load testing.
Meter Adjustment: Users can adjust the voltmeter and ammeter pointers to zero using the adjusting screws on the meter faces if they are not at zero before testing.

Maintenance Features:

Cooling: The manual highlights that the tester generates a large amount of heat during load tests and requires cooling time between uses to prevent damage.
Storage: Recommends storing the battery tester in a cool, dry location to prevent moisture buildup in the carbon pile.

Safety Precautions (Integrated into Usage):

The manual places a strong emphasis on safety due to the inherent risks associated with lead-acid batteries, including explosive gases and corrosive sulfuric acid.

Eye Protection: "CAUTION: ALWAYS WEAR EYE PROTECTION" is prominently displayed. The manual further specifies wearing "Approved Eye Protection, Approved Gloves and Protective Apron" when working near or testing a battery.
Explosive Gases: Warns of "A RISK OF EXPLOSIVE GASES" and instructs users to test in well-ventilated areas, avoid smoking, sparks, or open flames near batteries, and turn off the tester before connecting/disconnecting.
Sulfuric Acid: Details immediate first aid for acid contact with eyes (flood with cool running water for 10 minutes, seek medical attention) and skin (remove contaminated clothing, run cool water for 10 minutes). It also advises washing hands thoroughly after handling batteries and neutralizing acid spills with baking soda or household ammonia.
Tool Handling: Cautions against using tools near a battery that could cause sparks or short circuits.
Personal Items: Advises removing metal jewelry (rings, bracelets, necklaces, watches) to prevent short circuits and severe burns.

The FJC Carbon Pile Battery Tester is a robust tool designed for comprehensive battery and charging system diagnostics, with a strong emphasis on user safety and proper operational procedures. It is warranted for 6 months from the date of purchase against defects in material and workmanship under normal use and service.

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