OTC Tools 3182 User manual

3182
Digital Battery Load Tester
Test Time: 10 seconds Max Time: 15 seconds
Digital 130 Amp Battery Load/Alternator Tester
Load Switch
OPERATING INSTRUCTIONS

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When Working on Vehicles
• Always wear approved eye protection.
• Always operate the vehicle in a well-ventilated area. Do not inhale exhaust
gases—they are very poisonous!
• Neversmokeorhaveopenamesnearvehicle.Vaporsfromgasolineandcharging
batteriesarehighlyammableandexplosive.Alwayskeepareextinguishersuitable
forgasoline/electrical/chemicalreshandy.
• Alwayskeepyourself,tools,andtestequipmentawayfromallmovingorhotengine
parts.
• Neverlaytoolsonvehiclebattery.Youmayshorttheterminalstogether,causing
harmtoyourself,thetools,orthebattery.
• Always turn ignition key OFF when connecting or disconnecting electrical
components,unlessotherwiseinstructed.
• Keep away from engine cooling fan. On some vehicles, the fan may start up
unexpectedly.
• Neverleavevehicleunattendedwhilerunningtests.
• AlwaysmakesurethevehicleisinPark(automatictransmission)orNeutral(manual
transmission)andthattheparking brakeisrmlyset.Blockthedrivewheels.
• Alwaysfollowvehiclemanufacturer’swarnings,cautions,andserviceprocedures.
Additional Precautions When Testing
• Discharged batteries will freeze. Store batteries above 32°F (0°C) or maintain
batteriesinachargedcondition.
• TheBatteryLoadTesterbecomeshotduringtest.Allowittocoolbetweentests.
Thedisplaybeginsdimmingwhenthetesterisnotallowedtocool.Repeateduse
intheoverheatedconditioncandamagethetester’selectronics.
• Lead-acid batteries contain sulfuric-acid as the electrolyte.The electrolyte is
extremelycorrosiveandevolvesoxygenandhydrogenduringcharging,whichcan
igniteandcauseanexplosion.Haveventilationandkeepamesandsparksaway
fromchargingbattery.Followthemanufacturer’schargingprocedures.
• Ifelectrolytecontactsskin,immediatelyrinsewithwater.Ifelectrolytecontactseyes,
usheyeswithwaterandcontactphysician.Whenhandlingbatteries,weareye
protection,chemicalresistantglovesandprotectiveclothing.
DISCLAIMER!
Duetoinherentdangersassociatedwithautomotivemaintenanceprocedures,
themanufacturerandallpartiesinvolvedwiththedistributionand/orsaleof
thisequipmentwillnotbeheldliableorresponsible,eitherwhollyorinpart,
foranyinjury,damageorclaimsresultinginitsperformanceortheuseofthe
instructionscontainedinthismanual.
SAFETY PRECAUTIONS

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Battery Load Tester
The3182DigitalBatteryLoadTesterisahand-held,diagnostictoolusedtotest12V
(volt)and6Vlead-acidtypeautomotivebatteries.A10-secondtestdeterminesthe
conditionofthebattery:Good,WeakorBad.Furthertestingwillidentifypossible
problemsinthechargingandstartingsystems.Testscanbeperformedonfully
orpartiallychargedbatteriesbyinspectingtheelectrolyteoropen-circuitvoltage
andadjustingthevaluesfortemperaturesotherthan70°F(21.1°C).
• Iftheelectrolyteisaccessible,measureitsspecicgravitywithahydrometer.
Thespecicgravityreadingshouldbe1.225orhigherat70°F(21.1°C).For
every10°F(5.6°C)above/below70°F(21.1°C),add/subtract0.004to/fromthe
reading.
• Theopen-circuitvoltageshouldbeatleast12.45Vat70°F(21.1°C).
TheBatteryLoadTestercontainsafour-characterLCD(liquidcrystaldisplay)to
displaybatteryvoltage,aswitchtoapplythetestloadandaredLEDthatisused
toindicatetheconditionofthealternator.Thetesterispoweredbythebattery
undertest.
CAUTION!
• Test procedures and information provided in this manual are intended
as general guidelines for engine tune-up and adjustments only. Consult
the applicable vehicle service manuals for all specic tests.
• Before testing, read and follow all safety precautions.
• Do not activate and hold the load switch for more than 15 seconds.
This will overload the tester resulting in damage and void the warranty.
Test Preparation
Multi-Battery Systems
Inallmultiplebatterysystems,allbatteriesmustbetestedseparately.Batteries
may be connected in series, parallel or a combination of both. Only batteries
connectedinseriesmayremainconnectedduringtest.See Figure 1.
Forseriesconnections,allbatteriesareconnectedfromthenegative(-)terminal
ofonebattery,tothepositive(+)terminaloftheother.Onlythenegativeterminal
oftherstbatteryandthepositiveterminalofthelastbatteryaretobeconnected
tothevehicle.Anynumberofbatteriesmaybeconnectedinaseries.However,
each battery must be tested separately.
Forallotherconnections(paralleloracombinationofparallelandseries),the
batteries mustbedisconnectedandelectricallyisolatedfromeachother.
TO VEHICLE POWER TO VEHICLE GROUND
POS NEG POS NEG POS NEG
Figure 1 Multi-Battery Test Conguration

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Vehicle Battery
1.TurnignitionkeyOFF;notintheACCESSORIES
position (Figure 2).EngineneedstobeOFFand
all electrical loads must be removed from the
batteryforpropertesting.Ifloadsstillexist,refer
tothevehiclesoperatorandservicemanual.
2.Ifbatteryisbeingcharged,thenstop,turncharger
OFFanddisconnectclampsorleads.Thebattery
cannotbetestedwhilebeingcharged.
3.Theconnectionsmustbecleanandmustmake
goodcontacttoachievecorrecttestresults.
4.On side-post type batteries, install terminal stud adapters. These are not
included,butareavailableatmostautomotivepartsstores.
Battery Temperature
The most accurate test results will be obtained when battery temperature is
at approximately 70°F (21.1°C). If testing battery between 70°F (21.1°C) and
40°F(4.4°C),add0.1voltforevery10°F(5.6°C)below70°F.Iftestingabattery
between70°F(21.1°C)and100°F(37.8°C),subtract0.1Vforevery10°F(5.6°C)
above70°F(21.1°C).
Load Test
1.Connect the tester’s Black
clamptothenegative(-)battery
terminal and the Red clamp to
thepositive(+)batteryterminal
(Figure 3).Makesurebothjaws
makegoodcontact.Ifrequired,
rock clamps back and forth to
improve connection.
2.TheLCDdisplaywillturnonand
displaythebatteryvoltage.Thebatterymustbeatleast75%chargedbefore
conductingtheLoadTest.At70°F(21.1°C),thevoltageshouldbeatleast12.45V
(or6.23Vfora6Vbattery).Remembertoadjustvoltagefortemperaturesother
than70°F(21.1°C).
CAUTION!
• The Battery Load Tester becomes hot when applying the load.
Allow tester to cool between discharges; about 2 minutes. In warm
temperatures, allow more time to cool. If overheating occurs, the LCD
might temporarily become dim. After cooling down, the tester’s LCD
will return to normal.
• Do not activate and hold the load switch for more than 15 seconds.
This will overload the tester resulting in damage and void the warranty.
Figure 2 Engine OFF
Figure 3 Battery Connections

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3.PressandholdtheLOAD SWITCHfor
10seconds.RefertoFigure 4.
4.Observe the voltage on the LCD and
note the value. Release the LOAD
SWITCHimmediatelyafterreadingthe
display.
5.Disconnect the Red clamp from the
batteryandthentheBlackclamp.
6.Figure 5showstherangefora500CCA
(Cold-CrankingAmperage) battery
tested at 70°F (21.1°C). For batteries
ratedatotherCCAvalues,subtract0.1V
forevery100CCAbelow500CCAfrom
thevaluesshowninFigure 5.Add0.1V
forevery100CCAabove500CCA.
 IfthevoltageisintheWEAKregion,then
thebatteryisprobablydischargedand
needstobechargedbeforetesting.
• Disconnecttesterandchargebattery;
followbatterychargermanufacturer’s
instructionsforchargingprocedures.
WARNING!
Charging a battery with a bad cell may cause severe personal injury and
damage to vehicle and/or equipment.
• Disconnectcharger,reconnecttesterandretest.Ifthevoltageremainslow,
thenthebatteryisnotacceptingachargeandshouldbereplaced.
Test Results
GOOD - means the battery is in
good condition and should start
the vehicle in any environment.
WEAK - Indicates the battery is
dischargedandrequirescharging.
Chargebatteryandthenretest.
• IfbatterytestsWEAKasecond
time,thiscouldindicateoneor
more cells are bad and battery
mustbereplaced.
• If battery reads GOOD, the
battery was not su󰀩ciently
chargedduringthersttest.
BAD - Indicates the battery is
deeply discharged and requires
acompletechargeorthebattery
isbadandrequiresreplacement.Checkthefollowing(onpage6)andretest.
Test Time: 10 seconds Max Time: 15 seconds
Digital 130 Amp Battery Load/Alternator Tester
Load Switch
Load Switch
Figure 4 Load Switch and Display
Figure 5 500 CCA Test Results at 70°F (21.1°C)
GOOD
WEAK
BAD
10.00V
6.10V 3.05V
5.00V
12V Battery 6V Battery

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•Batteryclampsaresecurelyfastenedtotheterminals.
•Terminalsarecleanandfreeofdebrisforagoodelectricalcontinuity.
•Ifaside-posttypebatteryisbeingtested,verifytheterminalstudadaptersare
screwedintightly.
Ifnofaultisdetected,thenchargebatteryandretestbeforereplacingthebattery.
Iftesterstillindicatesabadbattery,thenreplacementisrequired.
NOTE: A WEAK or BAD indication may be due to excessive resistance
caused by a bad connection or corrosion between battery cables and the
battery posts. Remove battery cables from battery, connect the tester directly
to the posts and retest.
Starting Test
Thistestevaluatesthevehicle’sstartingsystembymeasuringthebatteryvoltage
whilecrankingtheengine.
1.Whileobservingpolarity,connectthetesteracrossthevehicle’sbatteryposts:
Redtopositive(+),Blacktonegative(-).RefertoFigure 6.
2.Disable the ignition system to prevent the vehicle from starting. Refer to a
vehicleservicemanualifnecessary.
Figure 6 Starting Test and Charging Test Setup

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3.HaveanassistantturntheignitionswitchtotheStartPositionandcrankengine
for15seconds.Ifworkingalone,usearemotestarterswitch.Do not press the
Load Switch.Observethebatteryvoltageindicatedonthedisplay.
4.Ahealthystartingsystem,with a good, fully charged battery,shouldreadabove
9.0Vduringthistest.
5.Readingsbelow9.0Vmayindicateaprobleminthestartingsystem.Recharge
batteryandrepeatthistest.Ifvoltagereadingsstillremainbelow9.0V,then
probablyeitherthebatteryisbad(performtheLoadTest),thestarterisdefective
or the cables are loose or corroded.
Charging Test
Thistestmeasuresthebatteryvoltagewhiletheengineisrunningtodetermine
ifthechargingsystemisoperatingproperly.
1.Startthevehicleandallowittowarm-up.Thismaytake10to15minutes.
2.TurnengineOFF.
3.WhenperformingtheChargingTest,thebatteryshouldbepartiallydischarged.
TurntheignitionswitchtotheACCESSORIESpositionandturnheadlightsON
andfantoHIGHfor1minute.
4.Whendone,turnheadlightsandfanOFFandthenturnignitionswitchtothe
OFFposition.
5.Whileobservingpolarity,connectthetesteracrossthebatteryposts:Redto
positive(+),Blacktonegative(-).RefertoFigure 6.
6.Start engine and runatfast-idle (1200-1500 RPM).Ahealthy 12V charging
systemshouldmaintainreadingsbetween13.5V and 15.5V.
Proper Charging System Operation
Within several minutes, the voltage will gradually increase to the regulated
voltagerangeof13.5Vto15.5V.Ina6Vsystem,thevoltageshouldgradually
risetotheregulatedvoltagerangeof6.7Vto7.4V.
Incorrect Charging System Operation
Low Regulated Voltage: Ifafterseveralminutes,thevoltageisbelow13.5V
fora12Vsystem(6.7Vfora6Vsystem),thanaproblemexistswitheitherthe
charging system or battery. Perform the Load Test on the battery and then
repeattheChargingTest.
High Regulated Voltage: Ifthevoltageisabovetheregulatedvoltagelimit
(15.5Vfora12Vsystem,7.4Vfora6Vsystem),thenaproblemexistsinthe
chargingsystem.Damagetothevehicleelectricalsystemmayresultfromthe
excessivelyhighvoltage.
AdecisiontoREPLACEthealternatororotherelectricalsystemcomponents
shouldnotbebasedsolelyonthesetestresults.Refertotheapplicablevehicle
servicemanualforadditionaltestandtroubleshootingprocedures.

80002-000-2407 Rev B
Figure 7 Alternator Test Setup
Alternator Test
Thistestidentiesproblemsassociatedwiththealternator.
1.AsshowninFigure 7,connectthetester’sclampstothevehicle’sbatteryposts:
Redtopositive(+),Blacktonegative(-).Connectthetestleadtothetester
andpositiveterminalonalternator.OnGMalternators,attachthetestleadto
terminalNº1withoutdisconnectingtheplug.
2.Startengineandallowittoidle.
3.IfaGMalternatorisbeingtested,observethetester’sRedLEDanddo not
press the LOAD SWITCH.Otherwise,continuewithStep4.
•IftheLEDashesOnandgoesOFF,ornevercomesON,thentheDiode
Trioisfunctioningproperly.
•IftheLEDstaysON,thentheDiodeTriomightbedefective.Thealternator
needs repair or replacement.
4.Revtheenginetoafastidle(1200-1500RPM).
CAUTION!
• The Battery Load Tester becomes hot when applying the load.
Allow tester to cool between discharges; about 2 minutes. In warm
temperatures, allow more time to cool. If overheating occurs, the LCD
might temporarily become dim. After cooling down, the tester’s LCD
will return to normal.
• Do not activate and hold the load switch for more than 15 seconds.
This will overload the tester resulting in damage and void the warranty.
5.PressandholdLOAD SWITCHontesterfor5secondsandobservethetester’s
RedLED.Whendone,turnengineOFFanddisconnectthetestleads.
•IftheLEDashesONandthengoesOFF,ornevercomesON,thenthe
diodes(rectiers)arefunctioningproperly.
• If the LED stays ON or ashes continuously, then one or more diodes
(rectiers) are defective. Repair or replace the alternator and/or voltage
regulator.