Sealey Auto service bt91/7c User manual

p WARNING! Ensure you read, understand and apply the safety and operational

instructions before connecting the tester clamps to the battery. Only when you

are sure that you understand the procedures is it safe to proceed with the testing process.

3.1. Preparation

3.1.1. Check battery casing for cracks or leakage and confirm that it is 6 or 12 volts.

3.1.2. Clean battery terminals.

3.1.3. If possible, check electrolyte levels and top up with distilled water as necessary.

3.2. Connection

pWARNING! Ensure vehicle, or battery, is in a well ventilated area before starting to test.

3.2.1. Attach positive (red) clamp to positive (+) battery terminal and negative (black) clamp to negative (-)

terminal. Slightly twist clamps on terminals two or three times to ensure a good electrical contact and

a firm grip. Correct connection is indicated by the meter pointer (fig.1) moving to the right, up the scale.

If the pointer moves to the left then the clamps should be reversed. If the pointer does not move at all

there is either a bad connection or the battery is completely dead.

3.2.2. Ensure that the clamp cables are clear of hot or moving engine parts, particularly if a starter or charging

test is to be carried out. Ventilation slots in tester casing should be unobstructed, meter should be easily

visible and load switch accessible.

1.1. PERSONAL PRECAUTIONS

3Ensure there is another person within hearing range of your voice and close enough to come to your aid, should a problem

arise when working near a lead-acid battery.

3Wear safety eye protection and protective clothing. Avoid touching eyes while working near battery.

3Have fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

3Wash immediately with soap and water if battery acid contacts skin or clothing. If acid enters eye, flush eye immediately with cool, clean running water for at

least 15 minutes and seek immediate medical attention.

3Remove personal metallic items such as rings, bracelets, necklaces and watches. A lead-acid battery can produce a short-circuit current high enough to weld a

ring or the like to metal, which would cause severe burns.

3Ensure hands and clothing (especially belts) are clear of fan blades and other moving or hot parts of the engine, remove ties and contain long hair.

7DO NOT smoke or allow a spark or flame in the vicinity of battery or engine.

1.2. GENERAL SAFETY INSTRUCTIONS

3Familiarise yourself with the application and limitations of the tester as well as the potential hazards. Also refer to the vehicle manufacturers handbook. IF IN ANY

DOUBT CONSULT AN ELECTRICIAN.

3Ensure the tester is in good order and condition before use. If in any doubt do not use the unit and contact an electrician.

3Only use recommended attachments and parts. To use non-recommended items may be dangerous and will invalidate your warranty.

3Ensure the tester load switch is Off before attaching/detaching the power clamps to/from the battery terminals.

3Keep tools and other items away from the engine and ensure you can see the battery and working parts of the engine clearly.

3Confirm that the battery to be tested is 6 or 12 volt and not 24 volt before attaching clamps to battery terminals.

3If the tester receives a sharp knock or blow the unit must be checked by a qualified service agent before use.

3If the battery terminals are corroded or dirty clean them before attaching the clamps.

3Keep children and unauthorised persons away from the work area.

7DO NOT dis-assemble the tester for any reason. The tester must only be checked by qualified service personnel.

pWARNING! To prevent the risk of sparking, short circuit and possible explosion DO NOT drop metal tools in the battery area, or allow them to touch the battery terminals.

7DO NOT cross connect leads from tester to battery. Ensure positive (+/RED) is to positive and negative (-/BLACK) is to negative. If symbols cannot be

distinguished, remember that the negative terminal is the one directly connected to the vehicle bodywork.

7DO NOT pull the cables or clamps from the battery terminals.

7DO NOT use the tester outdoors, or in damp, or wet locations and DO NOT use within the vicinity of flammable liquids or gases.

3Ensure there is effective ventilation to prevent a build-up of explosive gases and do not cover or obstruct tester ventilation louvres.

7DO NOT use the tester for a task for which it is not designed.

3When not in use, store the tester carefully in a safe, dry, childproof location.

7DO NOT operate the load switch for more than 10 seconds at a time (failure to release the switch after 10 seconds may result in the switch burning out and

invalidating your warranty).

INSTRUCTIONS FOR:

6V & 12V BATTERY TESTER

MODEL: BT91/7C

Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions

and properly maintained, give you years of trouble free performance.

1. SAFETY INSTRUCTIONS

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND CAUTIONS. USE THE PRODUCT

CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL

INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

DANGER! BE AWARE, LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS

VERY IMPORTANT TO READ AND FOLLOW THESE INSTRUCTIONS CAREFULLY, EACH TIME YOU USE THE BATTERY TESTER.

Follow these instructions and those published by the battery and vehicle manufacturers, and the maker of any equipment you intend to use in the vicinity

of the battery. Remember to review warning marks on all products and on engines.

The BT91/7C is a battery tester, accurate to ±2%, suitable for 6 and 12 volt lead-acid batteries.

The unit measures open circuit and under load voltages and can be used to check the condition

of the starting and charging systems. The battery load is switched into and out of circuit as

required, thereby eliminating arcing at the battery terminals.

3. OPERATION

2. INTRODUCTION

fig. 1

BT91/7C - 0008 - (1) - 150501

fig. 2

For Jack Sealey Ltd. Sole UK importer of Sealey Professional Tools.

BT91/7C - 0008 - (1) - 150501

01284 757500 01284 703534

E-mail:

sales@sealey.co.uk

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.

IMPORTANT: No liability is accepted for incorrect use of this equipment.

WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.

INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.

Sole UK Distributor,

Sealey Group,

Bury St. Edmunds, Suffolk.

Declaration of Conformity We, the sole UK importer, declare that the product listed below is in conformity with the following standards and directives.

The construction file for this product is held by the Manufacturer and may be

inspected, by a national authority, upon request to Jack Sealey Ltd.

6V & 12V Battery Tester

Model: BT91/7C

89/336/EEC EMC Directive

Signed by Mark Sweetman 15th May 2001

3.4. Load test chart

Load Test Result Battery Condition

OK - green, fig.1.F - 12v Battery capacity is good. May or may not be fully charged. Check electrolyte specific gravity to determine charge state.

fig.1.B - 6v If not fully charged check for charging system fault (para. 3.6) or electrical drain.

Bad or Weak - red or yellow, Battery capacity is unsatisfactory. Battery may be either: (1) defective or (2) partly discharged.

but reading steady. Check electrolyte specific gravity. If over 1.225 battery is defective. If under 1.225 recharge battery and retest. If cell-to-cell

fig.1.D/E - 12v specific gravity varies by more than 0.025 a cell defect may exist. If charging does not bring specific gravity to full charge

fig.1.A/C - 6v level battery is either sulphated or has lost active material.

Bad or Weak - red or yellow, Battery may be defective. Release load switch and note meter reaction. If voltage recovers to 12 volts (6 volts for 6 volt

but reading falling after battery) or more in a few seconds then battery is probably defective. If voltage recovers slowly battery may only be

10 secs. on load. discharged. Check electrolyte specific gravity and proceed as above.

3.5. Battery voltage/charge level

3.5.1. If the load test result indicates a battery fault allow battery to stabilize for a few minutes and then read the open circuit voltage - meter reading with load switch Off.

3.5.2. Compare the reading with the Voltage/Charge table below to get an estimation of the charge level.

Open Circuit Voltage Charge %

12 volt/6 volt battery

11.7/5.8 or lower . . . . . . . . . . . . . . . . . . .0

12.0/6.0 . . . . . . . . . . . . . . . . . . . . . . . . .25

12.2/6.1 . . . . . . . . . . . . . . . . . . . . . . . . .50

12.4/6.2 . . . . . . . . . . . . . . . . . . . . . . . . .75

12.6/6.3 or higher . . . . . . . . . . . . . . . . .100

3.5.3. The battery is considered charged at 75% or more. If it failed the load test with this charge it should be replaced. If the voltage indicates a charge level below

75% then charge the battery and load test again. If it fails this second test replace it.

3.6. Charging system (12 volt)

3.6.1. Start engine and allow to reach normal operating temperature. Switch off all accessories.

3.6.2. Run engine at 1200 to 1500rpm and note meter reading, which should be in the green OK sector (fig.1.H). DO NOT press the load switch.

3.6.3. Switch on head lights and heater fan (highest speed), meter reading should remain in the green OK sector.

3.6.4. A reading in the red sector to the left (fig.1.G) indicates a fault in the charging system which will cause the battery to be under charged. A reading in the red

sector to the right (fig.1.I) indicates a fault which will cause the battery to be over charged.

Note: Although not marked on the meter scale the OK range for a 6 volt charging system is 6.8 to 7.5 volts.

3.7. Starter motor (12 volt)

Note: This test requires that the battery is in good condition and is charged to at least 75% capacity.

3.7.1. Disable ignition system (remove fuse or similar) so that engine will not start.

3.7.2. Carry out a load test (para. 3.3.), if not already done, and note voltage reading.

3.7.3. Use the table on the meter (fig.1.J) to determine the equivalent minimum cranking voltage. Note that for engines of less than 3.25 litres take the next higher

figure. For example: a) 3.5 litre engine - load test result 11.0 volts, gives min. cranking voltage of 9.7 volts.

b) 1.5 litre engine - load test result 11.0 volts, gives min. cranking voltage of 10.2 volts

3.7.4. Operate the starter motor and note the voltage during cranking.

3.7.5. A reading below the minimum cranking voltage indicates that the starter motor is taking excessive current. This may be due to poor connections, to a faulty

motor or to the battery being too small for the vehicle.

3.7.6. After test reinstate ignition system.

Note: For a 6 volt system test as above and note load test voltage. Double this value and determine equivalent min. cranking voltage as in 3.7.3. Halve the figure to

give min. cranking voltage for the 6 volt system and then proceed from 3.7.4.

3.3. Battery load test

NOTE: ON THE FIRST LOAD TEST SMOKE MAY BE EMITTED FROM THE LOUVRES IN THE TESTER CASING. THIS IS OIL BURNING OFF THE LOAD COILS

AND IS NORMAL.

3.3.1. Press load switch (fig.2) and hold until meter reading stabilizes, or for a maximum of 10 seconds.(failure to release the switch after 10 seconds may result

in the switch burning out and your warranty being invalidated). Note meter reading and then release load switch.

3.3.2. Compare meter reading with load test chart (3.4) to determine battery condition.

Notes: a) For 12 volt batteries the green sector (fig. 1.F) border is marked with nominal cranking current from 300 to 500 amps and stepped in 50 amp intervals.