FJC 45135 User Manual

Page 1

INTRODUCTION

Your new Model 45135 Battery Diagnostic Tester employs conductance testing to determine the condition of the battery. The patented circuit eliminates the need for time consuming CCA input or conversions to other rating systems. When the

TEST button is pressed, the 45135 will immediately display BOTH the percent available capacity of the battery and the condition of the battery. The 45135 also tests 12/24/36V

alternator and starter systems.

YA2612A

Displays % Capacity &

DC Volts

Bar Graph Indicator

Low Volts Indicator

Battery Size Selector

Press to Test Battery

Battery Size Indicator

SPECIFICATIONS

Battery Size Range Auto: 390 to 650 CCA 40 to 60 Ah

Truck: >650 to 1700 CCA >60 to 250 Ah Battery Condition

Good: 80 to 100% Marginal: between 70 to 80%

Replace: below 70% DC Volt Range: 6V to 49.9V

DC Volts Accuracy: ± 2% Reading Capacity/Volts Display: 4 LED’s- 3 ½ Digit Bar-graph Display: 10 color-coded LEDs Operating Temperature: 32°F to 120°F Weight: .75 LBS Dimensions: 7.5” x 3.5” x 1” H Jaw Opening: 1.25”

User Manual

Model 45135

HEAVY DUTY

Battery Condition & Charging

System Tester

Tests 12V Auto and Truck Batteries

and12/24/36V charging systems

& 42V mild hybrid vehicles

RETURN FOR REPAIR POLICY

Every effort has been made to provide reliable, superior quality products. However, in the event your instrument requires repair, call FJC, Inc.:

For Service

704-664-3587

WARRANTY POLICY

The 45135 Battery Diagnostic Tester is warranted to be free of defects in materials and workmanship for a period of two years from the date of purchase. This warranty applies to all repairable instruments that have not been tampered with or damaged through improper use including unauthorized opening of the unit. Please ship warranty units that require repair freight prepaid to Service Center along with proof of purchase, return address, phone number and/or email address.

Made in USA S

Page 2

Checking Charging System

(Alternator)

CHARGING SYSTEM TEST

Note: Prior to performing this test, check the battery condition to make sure it is in good condition. (See In Vehicle Battery Test Instructions).

1. Check first for a loose, worn or broken alternator belt. If okay, proceed to #2.

2. Connect the red clip to the positive battery terminal and the black clip to the negative terminal and start engine. For series batteries connect the test clips as shown below.

3. With engine running and lights on, the real time alternator output voltage will be displayed. The reading should display between 13.0 and 15.0 volts for 12V charging systems.

Check manufacturer’s specifications for 24V and 36V

systems. NOTE: Consult shop manual for instructions on testing 42V mild hybrid systems.

4. Low charging voltage: check belts for slippage. Check connections from the alternator to the battery. If no problems are found, replace the alternator.

5. High charging voltage: Check for loose connections including the ground connection. If OK, replace the voltage regulator. Newer alternators house the regulator inside. In

this case replacing the alternator is necessary.

Series

Connection

Individual

Connection

Checking Battery Condition

Out of Vehicle Testing

1. Connect the red clip to the positive battery

post and the black clip to the negative post*. The battery voltage will be displayed. When

testing 24V/36V battery packs, connect to the battery posts for each individual 12V battery.

2. For AUTO batteries 390 to 650 CCA (40 to 60 Ah) no size selection is necessary (default size). The Auto indicator LED will be on.

For TRUCK batteries >650 to 1700 CCA (>60 to 250 Ah) press selector switch once. The LED indicator will switch to the TRUCK position.

3. Press and hold down the Test Button until the final reading is displayed.

The DIGITAL DISPLAY shows PERCENT AVAILABLE CAPACITY. The Display and

Bargraph will remain on until the Test Button is released.

4. The color--coded LED BARGRAPH will show GOOD (Green) MARGINAL (Yellow) or REPLACE (Red).

*When testing high capacity truck batteries, make sure clips

make a solid connection with battery post.

Note: Some batteries may display above 100%. This means that the available capacity is greater than the rated capacity

STARTER TEST

Note: Check the battery condition to make sure it is in good condition before performing this test. (See In-Vehicle Battery Test Instructions page 3).

1. Connect the red clip to the positive battery terminal and the black clip to the negative terminal. For series batteries connect the test clips as shown below.

2. Disengage the ignition. (Check manufacturer’s instructions). Read the voltage displayed while cranking the starter.

3. Cranking Voltage is Normal: For 12V systems the normal cranking voltage at the battery should be equal to or greater than 9.6 volts*.

4. Cranking voltage is Low: If the cranking voltage is less than 9.6 volts*, starting system has a problem. Check wires, connections and starter.

Check manufacturer’s specifications for 24V and 36V systems. NOTE: Consult shop manual for instructions on

testing 42V mild hybrid systems.

Converting to CCA, Ah, DIN, JIS, EN

If required, the available CCA or Ah, can easily be determined by multiplying the percent displayed times the battery’s original rating. For example, a 600 CCA battery with 80% capacity available would have 480 CCA (.80 x

600) available.

Series

Connection

Individual

Connection

Low Volt Indicator

Batteries that test Marginal or (just below Marginal) when the Low Volts LED indicator is on (below 12.3 Volts on 12V

systems and below 24.6 Volts on 24 Volts systems) should be recharged and retested for more accurate results.

Bad Cell Indicator

Capacity displayed below 20% and only 1 red led on the bargraph indicates that the battery has a defective cell.

Defective battery cells are usually open or shorted and the battery must be replaced.

In Vehicle Testing

(Checking Battery Condition)

1. Engine should be off. Turn off all accessory loads.

2. Remove surface charge (battery voltage is greater than 12.8 Volts) by turning on the headlights for 15 seconds.

3. Follow instructions for Out of Vehicle Testing (see Page 2).

4. When testing batteries in 24/36 Volt systems, test each individual 12V battery separately. The 45135 will display only the battery pack voltage when connected to two or more 12 Volt batteries-not the capacity of the pack when the TEST button is pressed.