AutoMeter SB-5 User manual

SB-52
Battery Load Tester
Instruction Manual
Simplied Check Program for Charging Systems
The SB-52 is a variable load battery tester that provides a simplied check
for alternator output and starter draw and circuit test.
24

CONGRATULATIONS
You have purchased a quality Battery/Circuit tester. In addition to
performing accurate battery load tests, this tester provides non-inductive
starter-draw and alternator output testing capabilities.
The automotive electrical system consists of a battery, starter, solenoid
(usually mounted on the starter), ignition switch, alternator and
connecting cables and wires. All parts of the electrical system must be
operating properly for a vehicle to provide dependable transportation.
Whenever a component fails, the whole system should be checked to
insure that the failure was not caused by another part of the system.
The SB-5 model is a simplied approach to test each component of the
electrical system. This insures that you will be making only the necessary
repairs, resulting in satised customers and increased business. To gain
a complete understanding of how this tester works, and to derive the
maximum benets from this unit, we recommend reading through the
entire instruction manual before testing.
Equipment Needed
This tester is the basic tool for charging system testing. The follow test
equipment items are also recommended in order to facilitate complete
and accurate results.
• Battery Charger
• Battery Clamp Spreader
• Battery Clamp Puller
• Battery Terminal Cleaner
• Hydrometer
2
23

Equipment Needed----------------------------------------------------2
Specications -----------------------------------------------------------3
Safety ---------------------------------------------------------------------4
Cause of Battery Failure ---------------------------------------------4
Battery Inspection and Visual Check -----------------------------5
Preliminary Notes------------------------------------------------------6
Controls and Functions-----------------------------------------------7
Battery State of Charge ----------------------------------------------8
Battery Load Test ------------------------------------------------------9
Starter Draw Test ---------------------------------------------------- 10
Alternator Test -------------------------------------------------------- 12
Starter Circuit Test--------------------------------------------------- 14
Appendix A ------------------------------------------------------------ 16
Appendix B
Battery Charging Guide --------------------------------- 17
Battery Voltage Chart ------------------------------------ 17
Appendix C Multiple Battery System Tests-------------------- 18
Service Information-------------------------------------------------- 20
Clamp Inspection and Maintenance ---------------------------- 22
Warranty --------------------------------------------------------------- 23
Contact Information -------------------------------------------------24
SPECIFICATIONS
Carbon Pile 12 volt 800 Amp capacity or 6 volt 400 Amp capacity
Volt Meter Accurate 0-16 Volt scale - Precise color coded, pass/fail indication
Amp Meter 0-800 Amp Scale
Load Knob Variable load with automatic load release
Timer 15 second timer button
Fan 5 in. with override switch
Load Clamps 800 Amp rating with vinyl coated red and black handles and
insulated jaws
Load Leads 5 ft. 2 gauge coax cable with internal 18 gauge conductor
Dimensions 10.5" x 9" x 10" metal case
Shipping Weight 22 lbs.
TABLE OF CONTENTS
22
3
Equipment Needed----------------------------------------------------2
Specications -----------------------------------------------------------3
Safety ---------------------------------------------------------------------4
Cause of Battery Failure ---------------------------------------------4
Battery Check and Visual Inspection -----------------------------5
Preliminary Notes------------------------------------------------------6
Controls and Functions-----------------------------------------------7
Battery State of Charge ----------------------------------------------8
Battery Load Test ------------------------------------------------------9
Starter Draw Test ------------------------------------------------10-11
Alternator Test ----------------------------------------------------12-13
Starter Circuit Test-----------------------------------------------14-15
Appendix A ------------------------------------------------------------ 16
Appendix B
Battery Charging Guide --------------------------------- 17
Battery Voltage Chart ------------------------------------ 17
Appendix C Multiple Battery System Tests----------------18-19
Service Information----------------------------------------------20-21
Clamp Inspection and Maintenance ---------------------------- 22
Warranty --------------------------------------------------------------- 23
Contact Information ------------------------------------------------- 24

SAFETY
Carefully read all operating instructions
before using the tester
Wear eye protection when working
around batteries.
Be sure each test is completed before
removing load clamps to prevent arcing
and potential explosion from battery
gasses. Never remove load clamps
while testing. Keep sparks, ames, or
cigarettes away from batteries.
Keep hair, hands, and clothing as well
as tester leads and cords away from
moving blades and belts.
Provide adequate ventilation to remove
car exhaust.
In extremely cold temperatures, check for frozen electrolytic uid
before applying load. Do not attempt to Load Test or charge a
battery under 20 degrees. Allow the battery to warm to room
temperature before testing or charging.
Warning! Never attach the unit to a battery that is connected to
any other tester or charging unit. Damage may result.
CAUSE OF BATTERY FAILURE
Incorrect Application: Wrong size battery may have inadequate
cold cranking rating for original vehicle specications.
Incorrect Installation: Loose battery hold-downs cause excessive
vibration, which can result in damage to the plates.
Improper Maintenance: Low electrolytic uid and corrosion on
battery connections can greatly reduce battery life and affect battery
performance.
Age of Battery: If the date code on the battery indicates it is fairly
old, the failure may be due to natural causes.
Overcharging: Overcharging caused by a high voltage regulator
setting or incorrect battery charging can cause excessive gassing,
heat and water loss.
Undercharging: Undercharging caused by a faulty charging
system or low voltage regulation can cause lead sulfate to gradually
build up and crystallize on the plates greatly reducing the battery’s
capacity and ability to be recharged.
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21

BATTERY INSPECTION
Important Note: A
known defective
battery must be
replaced before
proceeding with any
test on the charging
or starting system.
VISUAL CHECK
Inspect Battery for terminal
corrosion, loose or broken posts,
cracks in the case, loose hold-
downs, low electrolyte level,
moisture, and dirt around the
terminal.
Valid automotive electrical system testing depends on all the components
being in good operating condition. In addition, the battery MUST have
sufcient charge for testing. Carefully perform the following before
attempting any electrical diagnosis.
Inspect Belts for cracks, glazed surface and fraying. Tighten loose
belts. Inspect belt tensioner for proper alignment.
Inspect Starting System. Check starter, solenoid, and alternator for
loose connections, loose mounts and frayed or cracked wires.
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5

PRELIMINARY NOTES
If tester has not been used for a period of time, moisture may have
condensed between carbon pile discs. This will cause the tester to steam
a little during rst or second load application. This is normal and is not a
malfunction of the tester. (Do not confuse this with heat due to overloading
the tester.)
2. BATTERY RATING
Most batteries are rated in Cold
Crank Amps or Amp-Hours. This
tester uses a stabilized variable
load carbon pile that allows each
battery to be tested at its proper
rating. For batteries rated in Cold
Crank Amps, a load equal to one
half the rated CCA is applied using
the Amps scale on the meter. For
Amp-Hour rated batteries, a load
three times the Amp-Hour rating is
applied using the Amp scale.
3. BATTERY
4. TESTER HOOKUP
Take special care when connecting to
side terminal batteries. If necessary,
use a side post adapter to prevent
thread damage. When testing dual post
batteries always check the post to which
the system is attached. If a load test is
made from a post connection and the
alternator is mounted to side terminals
a battery load test can be completed,
but a continuity problem may still be
in the side terminals when testing the
alternator.
TEMPERATURE
The temperature of the electrolyte
and plates inside a battery affects
its output capability. As a result,
it is necessary for the service
technician to closely estimate the
battery’s temperature when testing.
This tester has temperature ranges
clearly shown on Pass/Fail bands,
so that accurate test results can be
obtained easily.
1. MOISTURE
6
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APPENDIX CONTROLS AND FUNCTIONS
TIMER LIGHT:
Indicates timer is on.
15 SECOND TIMER BUTTON:
Push to start the 15 second timer.
LOAD KNOB:
Turns the fan on and controls the amount of load during the test.
FAN OVERRIDE ON LIGHT:
Indicates when the fans override switch is on.
FAN OVERRIDE SWITCH:
The fan normally goes on automatically when the load knob is
turned on and when released the fan turns off automatically. In repeated
tests it is suggested that the fan override switch be turned on. This keeps
the fan on for better cooling.
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TIMER LIGHT FAN OVERIDE LIGHT
TIMER PUSH BUTTON FAN OVERIDE SWITCH
LOAD KNOB

BATTERY STATE OF CHARGE
The battery must have an adequate state of charge before a valid battery
load test can be performed. The state of charge can be measured with
a hydrometer (see Appendix A page 16), or checked by the “state of
charge” scale on the voltmeter for sealed batteries.
Read the 12 volt range (12 Volt Batteries) or the 6 volt range (6 Volt
batteries) on the voltmeter, If the meter reads on the left side, in the red
zone of the “state of charge” scale, the battery must be charged. See
Appendix B page 17 for charging. Charge at a current rate as shown
in Appendix B. This rate is determined by battery category type, which
relates to reserve capacity in minutes.
After charging the battery, the surface charge must be removed before
testing can begin. Surface charge will cause a higher voltage reading,
which is incorrect. To remove the surface charge, turn the load knob to
apply 1/2 the cold crank rating load or 3 times the amp-hour rating to
the battery for 5 seconds. Wait several minutes after removing load and
check “state of charge”. If the meter reads in the charge zone, replace
battery (see example above). If the voltmeter reads in the “test” band
(see example below), the battery is ready for the “battery load test”.
8
17

APPENDIX BATTERY LOAD TEST
1. Turn load knob to apply a load equal to 1/2 the Cold Crank rating or 3
times the Amp-Hour rating for 15 seconds.
2. Hold proper load for 15 seconds, observe the voltage reading, and
then immediately decrease the load until the fan stops and the
ammeter reads zero.
3. If the Voltmeter reads in the green zone for the approximate battery
temperature, the battery passed the load test (see example above).
If the Voltmeter reads in the red zone, replace the battery (see
example below). Use the battery Voltage Chart in Appendix B page
17 to compare test results.
NOTE: For Multiple Battery System Tests see Appendix C
WARNING: Be sure load is off before attaching or removing load clamps
to prevent arcing and potential explosion from battery gases. Always
shield eyes and keep sparks, ames or cigarettes away from batteries.
16
9
1

STARTER DRAW TEST
For proper starter functioning, it is important that all related connections
are clean and tight, and that the cable and its insulation are in good
condition.
On all starter circuit tests, disable ignition circuit by one of the
following methods:
1. DETERMINING THE LOADED VOLTAGE USING THE STARTER:
Crank engine and observe the voltmeter reading. Do not crank
engine over 7 seconds at one time to eliminate possible damage to
starter windings.
2. CHECKING THE AMPS USING THE TESTER TO DELIVER THE
SAME LOADED VOLTAGE: The tester is used as a load to simulate
the starter load. This is done by applying a load until the voltage
drops to the same voltage observed while cranking the engine. Thus,
the tester load amps indicated in the black 0-800 scale are the same
as the starter amp load. Read amps indicated on the scale while
load is applied (see example on page 11). This is the starter-draw
current. Compare amp draw to manufacturer specications.
• STD. IGNITION- (Points & Cond.): Ground coil output.
• ELEC. IGNITION- (Module): Disconnect 12V power supply.
• DIESEL: Disconnect 12V power supply to fuel shut-off
solenoid.
The battery voltage will drop when it is loaded by the starter or with the
tester. The Amp reading (when the tester yields the same loaded voltage
as the starter) is the starter draw.
10 15
2
LOAD VOLTS SAME
AS STARTER VOLTS

650A
STARTER CIRCUIT TEST STARTER DRAW TEST CONT.
Example:
1. With ignition disabled crank vehicle and observe lowest volt reading.
For this example, we’ll say it reads 11 volts.
2. Apply a load with the Load knob until voltmeter reads 11 volts (see
example page 10). Quickly read the ammeter. In this case it reads
240 amps. Remove the load (knob turned fully counterclockwise).
3. We now know the starter draw is 240 amps and that it is generally
within specications for a V8 gasoline engine (see Maximum Amps
chart on page 11).
Maximum Amps
If manufacturer’s specications are not available, the chart below can be
used as a general guideline for light duty engines and starters. Amounts
are in Amps.
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11

REGULATION:
To charge a battery, the alternator must produce a voltage higher than the
battery voltage to cause current to ow into it. Therefore, the voltage must
rise to the “OK” test zone of the ALT. & REG. TEST band.
Before testing, run the vehicles engine at fast idle with all the accessories
off for at least 5 minutes to recharge the battery and to stabilize the
temperature of the alternator. (Remember, the following tests are valid
only if the battery has passed the Battery Load Test (See page 9). For the
following tests, continue running the engine at fast idle).
The battery is recharged when the voltmeter reading has stabilized at its
highest reading. Observe the voltmeter reading in the “ALT. & REG. TEST”
band:
ALTERNATOR TEST
1. If in HI zone (See Figure A):
Apply a normal accessory
load, such as lights, heater
and wipers.
2. If the reading drops more
than 0.5 volts, there may be
a wiring and/or connector
problem between the
alternator output and battery
positive (+). If the alternator is
producing adequate charge,
and the pointer stays in
the OK band, the charging
system is OK, and the test is
complete (see Fig. B).
3. If the meter is in the low band
replace the alternator (see
Fig. C)
OUTPUT:
4. Apply a Load upon the
battery until the Volts drop to
12.6 to 12.8. At that moment,
read Amps and add the key
draw amps (10-20 Amps).
The Load Amps + Key Draw
Amps = Total alternator
output.
12
13
4
FIG. A
FIG. B
FIG. C

Troubleshooting Alternator (Hypothetical Situation)
Problem: Customer returns continually because his battery
keeps running down, but all battery and alternator tests pass.
Solutions:
• If alternator reads in the low end of the OK range, it is
working ne. For people driving short distances, however,
the battery may not charge fast enough, causing the battery
to run down slowly. A higher amperage alternator may be
necessary to insure faster charging.
• Some shorting or grounding may occur and slowly drain
battery. Use a low range ammeter and check to see that
no current ows from the battery with engine and all
accessories turned off (including clocks). If current is owing,
locate cause and repair. Look for such things as trunk, hood,
ashtray and glove compartment lights, bad switches, etc.
• Ammeters installed after vehicle manufacture may not
have sufcient wire gauge to carry current without causing
a voltage drop. This can reduce battery-charging rate,
Measure the voltage drop from battery positive to alternator
output terminal. If the drop is greater than 0.5 volts, and all
connections are clean and tight replace all wire between the
two points with wire that is one gauge heavier.
• Aftermarket accessories may add enough load to the
charging system to exceed alternator capacity (i.e., stereos,
telephones, defoggers, etc.). Replace alternator with one of
higher capacity.
Dual Battery System
• When load testing check each battery separately with cables
disconnected, so a problem with one battery is not masked
by another battery.
• Charging system should be checked with both batteries
connected.
• Accessories may be connected to one or both batteries. Be
alert to their wiring differences in testing for problems.
ALTERNATOR TEST
12
13

RED
BLACK
Disable ignition as indicated in the Starter-Draw Test on page 10.
1. Connect the tester as shown below. A with the RED clamp to battery
positive and the BLACK clamp to the terminal on the starter, which is
connected to the solenoid directly or by cable.
2. Observe the voltage reading while cranking the engine.
3. On most vehicles, the reading should not exceed 0.5 volts (see
example below).
4. If the voltage drop exceeds 0.5 volts, check the voltage drop through
each cable, across each connection including the solenoid.
5. Repair and/or replace as necessary.
STARTER CIRCUIT TEST
14 11
5

RED
BLACK
STARTER DRAW TEST
6. To check the ground circuit, connect the RED clamp directly to the
starter casing (this may require chipping paint to make a good
connection), and the BLACK clamp to the battery negative terminal
as shown in example below.
7. While cranking the engine, observe the voltmeter. The voltage drop
should not exceed 0.3 volts. The total of the two tests should not
exceed 0.8 volts. If positive says .5 and negative says .3 then the
total is .8 Volts.
Example:
0.5 volts on the positive circuit
+ 0.3 volts on the ground circuit
.8 total system voltage drop
10
15

APPENDIX
Check the electrolyte specic gravity with a
hydrometer. If the specic gravity measures
between 1.100 and 1.220, the battery must be
recharged. If the specic gravity is between 1.225
and 1.265, the battery is ok to test. If the hydrometer
has a temperature correction chart, be sure to adjust
the reading for the battery’s temperature.
Variance of specic gravity between cells is not
signicant on discharged batteries (batteries with
specic gravities below 1.225). However, if there is
a variance of 50 points (0.050) in a battery whose
specic gravity is 1225 or more, that battery is
defective.
NOTE: A defective battery must be replaced before
proceeding with any electrical system tests.
HYDROMETER METHOD
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9
A

817
APPENDIX
Above 250 minutes
BATTERY CHARGING GUIDE
(6 and 12 Volt Batteries)
BATTERY CATEGORY CHARGE BATTERY
(RESERVE CAPACITY MINUTES) At either rate and time shown
Recommended charging rate and time for fully discharged batteries. Par-
tially discharged batteries will require less charging time.
80 minutes or less 14 hrs. at 5 Amps
7 hrs. at 10 Amps
80 to l25 minutes 20 hrs. at 5 Amps
10 hrs. at 10 Amps
125 to 170 minutes 28 hrs. at 5 Amps
14 hrs. at 10 Amps
170 to 250 minutes 42 hrs. at 5 Amps
21 hrs. at 10 Amps
33 hrs. at 10 Amps
CAUTION Exceeding the recommended charging rates can damage
the battery plates and generate potentially explosive
gases.
BATTERY VOLTAGE CHART
ESTIMATED
ELECTROLYTE
TEMPERATURE
MINIMUM REQUIRED VOLTAGE
UNDER 15 SEC. LOAD
6 VOLT 12 VOLT
70° F or above
60° F
50° F
4.8
4.75
4.7
9.6
9.5
9.4
40° F
30° F
20° F
4.65
4.6
4.55
9.3
9.2
9.1
10° F
0° F
4.5
4.25
8.9
8.5
B

BLACK RED
6 Volts6 Volts 6 Volts
Series 6 Volt
Batteries Series 6 Volt Series 6 Volt
In Parallel
APPENDIX
MULTIPLE BATTERY SYSTEM TESTS
6 Volt Battery Test
Using Two 6 Volt
Batteries In Series
(12 Volt System)
NOTE:
Regardless of the conguration all Six Volt Batteries
are checked and load tested individually using the
6 volt scale. Follow battery load test procedure on
page 9.
6 VOLT BATTERY LOAD TEST
In heavy duty applications, 6 and 12 volt charging systems are created
by combining 6 and 12 Volt batteries in various combinations.
For a valid test, batteries must be tested individually, and the charging
system must be tested at its rated voltage (6 or 12 Volts).
CAUTION: Care must be taken when disconnecting battery cables to
prevent shorting of loose cables to ground or positive. Arcing caused by
shorting cables can ignite hydrogen gas found in batteries and cause an
explosion.
The proper way to prevent arcing at battery is by disconnecting the
ground cable at the chassis or engine block and preventing it from
contacting any metal. Then the remaining cables can be disconnected
safely at each battery.
WARNING: Be sure load is off before attaching or removing load clamps
to prevent arcing and potential explosion from battery gases. Always
shield eyes and keep sparks, ames or cigarettes away from batteries.
18 7
C

BLACK RED
6 Volts6 Volts 6 Volts
BLACK RED
6 or 12 Volt
Battery Parallel 6 or 12 Volt Batteries
ALTERNATOR TESTS
12 Volt System Test
Using Two 6 Volt
Batteries In Series
Using the hookup above follow test procedures on page 12.
6 or 12 Volt System Tests
Using Single Or Multiple
Batteries Connected In Parallel
On 6 Volt systems use the 6
Volt scale
Use the scale appropriate
for the system test. Follow
the test procedures on
page 12.
On 12 Volt Systems use the
12 Volt scale.
6
19

SERVICE INFORMATION
Warranty claims to Auto Meter must be transportation prepaid and
accompanied by dated proof of purchase. This warranty applies only to
the original purchaser and is non-transferable.
Damage incurred during return shipment is not covered under this
warranty. It is the responsibility of the shipper (customer returning tester)
to package the tester properly to prevent damage during return shipment.
Repair costs for such damages will be charged back to shipper (cus-
tomer returning tester).
Before packing tester for return shipment, tighten load knob and
secure to prevent breakage of carbon discs during shipment due to rat-
tling. Also protect the meters and add plenty of over-pack cushioning
such as crumpled-up newspaper.
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