User’s Manual
Model 1855
Variable Load Battery
and Systems Tester
WARNING
Failure to follow instructions may
cause damage or explosion,
always shield eyes. Read entire
instruction manual before use.
Warning: This product contains chemicals,
including lead, known to the State of
California to cause cancer, birth defects
and other reproductive harm.
Wash hands after handling.
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 model 1855 is a simplified approach to test each component of the
electrical system. This insures that you will be making only the necessary
repairs, resulting in satisfied customers and increased business. To gain
a complete under­standing of how this tester works, and to derive the
maximum benefits 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 following 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
TABLE OF CONTENTS
Equipment Needed-----------------------------------------------------2
Specifications------------------------------------------------------------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
Volt Meter
Amp Meter
Load Knob
Timer
Fan
Load Clamps
12 Volt 800 Amp capacity or 6 Volt 400 Amp capacity
Accurate 0-16 Volt scale - Precise color coded, pass/fail indication
0-800 Amp Scale
Variable load with automatic load release
15 second timer button
5 in. with override switch
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.
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, flames, 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 fluid
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 specifications.
Incorrect Installation: Loose battery hold-downs cause excessive
vibration, which can result in damage to the plates.
Improper Maintenance: Low electrolytic fluid 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.
BATTERY INSPECTION
Valid automotive electrical system testing depends on all the components
being in good operating condition. In addition, the battery MUST have
sufficient charge for testing. Carefully perform the following before
attempting any electrical diagnosis.
VISUAL CHECK
Inspect Battery for terminal
corrosion, loose or broken posts,
cracks in the case, loose holddowns, low electrolyte level,
moisture, and dirt around the
terminal.
Important Note: A
known defective
battery must be
replaced before
proceeding with any
test on the charging
or starting system.
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.
PRELIMINARY NOTES
1. MOISTURE
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 first 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
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.
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.
CONTROLS AND FUNCTIONS
TIMER LIGHT
FAN OVERIDE LIGHT
LOAD KNOB
TIMER PUSH BUTTON
FAN OVERIDE SWITCH
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.
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 meter reads in the “test” band (see
example below), the battery is ready for the “battery load test”.
1
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. Holding 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, flames or cig­arettes away from batteries.
2
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:
• STD. IGNITION (Points & Cond.): Ground coil output.
• ELEC. IGNITION (Module): Disconnect 12V power supply.
• DIESEL: Disconnect 12V power supply to fuel shut-off solenoid.
NOTE: On late-model vehicles, this will set a trouble code that must be reset/erased.
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.
LOAD VOLTS SAME
AS STARTER VOLTS
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 specifications.
10
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 specifications for a V8 gasoline engine (see
Maximum Amps chart below).
Maximum Amps
If manufacturer’s specifications are not available, the chart below can
be used as a general guideline for light duty engines and starters.
Amounts are in Amps.
650A
11
4
ALTERNATOR TEST
To charge a battery, the alternator must produce a voltage higher than
the battery voltage to cause current to flow into it. Therefore, the voltage
must rise to the “OK” test zone of the ALT. & REG. TEST band.
Before testing, run the vehicle’s 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:
REGULATION:
1. If in HI zone (See Figure A):
Apply a normal accessory
load, such as lights, heater
and wipers.
FIG. A
FIG. B
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:
FIG. C
12
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.
Troubleshooting: Alternator (Hypothetical Situation)
Problem: Customer returns continually because his battery
keeps running down, but all battery and alternator tests pass.
Solutions:
alternator reads in the low end of the OK range, it is
• Ifworking
fine. 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.
shorting or grounding may occur and slowly drain
• Some
battery. Use a low range ammeter and check to see
that no current flows from the battery with engine and
all accessories turned off (including clocks). If current is
flowing, locate cause and repair. Look for such things as
trunk, hood, ashtray and glove compartment lights, bad
switches, etc.
installed after vehicle manufacture may not
• Alternators
have sufficient 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.
accessories may add enough load to the
• Aftermarket
charging system to exceed alternator capacity (i.e., stereos,
telephones, defoggers, etc.). Replace alternator with one of
higher capacity.
Dual Battery System
load testing, check each battery separately with
• When
cables disconnected, so a problem with one battery is not
masked by another battery.
system should be checked with both batteries
• Charging
connected.
•
Accessories may be connected to one or both batteries. Be
alert to their wiring differences in testing for problems.
13
5
STARTER CIRCUIT TEST
Disable ignition as indicated in the Starter Draw Test on page 10.
1. Connect the tester as shown below, 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.
RED
BLACK
2. Observe the voltage reading while cranking the engine.
3. On most vehicles, the voltage drop 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 and across each connection, including the
solenoid.
14
5. Repair and/or replace as necessary.
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.
BLACK
RED
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 0.5 and negative says 0.3 then
the total is 0.8 Volts.
Example:
0.5 volts on the positive circuit
+ 0.3 volts on the ground circuit
0.8 total system voltage drop
15
A
APPENDIX
HYDROMETER METHOD
Check the electrolyte specific gravity with a
hydrometer. If the specific gravity measures
between 1.100 and 1.220, the battery must be
recharged. If the specific 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.
NOTE: Be sure to check each cell on the battery.
Variance of specific gravity between cells is not
significant on discharged batteries (batteries with
specific gravities below 1.225). However, if there is
a variance of 50 points (0.050) in a battery whose
specific gravity is 1225 or more, that battery is
defective.
NOTE: A defective battery must be replaced before
proceeding with any electrical system tests.
16
B
APPENDIX
BATTERY CHARGING GUIDE
(6 and 12 Volt Batteries)
Recommended charging rate and time for fully discharged batteries.
Partially discharged batteries will require less charging time.
BATTERY CATEGORY
(RESERVE CAPACITY MINUTES)
80 minutes or less
CHARGE BATTERY
At either rate and time shown
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
Above 250 minutes
33 hrs. at 10 Amps
CAUTION: Always consult vehicle and battery charger owner’s
manuals prior to the charging process. 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
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
17
C
APPENDIX
MULTIPLE BATTERY SYSTEM TESTS
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, flames or cigarettes away from batteries.
6 VOLT BATTERY LOAD TEST
6 Volt Battery Test
Using Two 6 Volt
Batteries In Series
(12 Volt System)
BLACK
RED
6 Volts
6 Volts
NOTE:
Regardless of the configuration, all 6 Volt Batteries
are checked and load tested individually using the
6 Volt scale. Follow battery load test procedure on
page 9.
18
Series 6 Volt�
Batteries
Series 6
�
ALTERNATOR TESTS
BLACK
RED
12 Volt System Test
Using Two 6 Volt
Batteries In Series
6 Volts
6 Volts
Using the hookup above, follow test procedures on page 12.
BLACK RED
6 or 12 Volt System Tests
Using Single Or Multiple
Batteries Connected In Parallel
6 or 12 Volt�
Battery
Parallel 6 or 12 Volt Batteries�
� �
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.
19
SERVICE INFORMATION
Warranty claims to Clore Automotive must be frieght prepaid and
accompanied by dated proof of purchase. Product warranty applies only
the original purchaser and is non-transferable.
Damage incurred during return shipment is not covered under
the product 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 (customer returning tester).
Before packing tester for return shipment, tighten load knob to prevent
breakage of carbon discs during shipment due to rattling. Also protect
the meters and add plenty of over-pack cushioning such as crumpled-up
newspaper.
20
Cardboard load holder for shipping
In the event your tester needs to be returned to Auto Meter Service,
it must be properly packaged and protected to avoid damage during
shipment. Failure to follow these steps will allow the carbon disks to rattle
freely during shipment and cause breakage. Before packing the tester
for return shipment, turn load knob fully clockwise until it stops, hold in
position and slip a snugly fit cardboard holder over the load knob. This
will then rest against the cables and prevent the load knob from turning
back. The load knob holder must be 3-1/2” by 9-3/4” with a 2-3/16” hole
cut out in the center and slightly off set (copy and use template). Please
use a thick enough piece of cardboard, preferably corrugated, to prevent
bending and slippage of the load knob.
21
CLAMP INSPECTION and MAINTANENCE
IMPORTANT: Both jaws of each clamp must firmly
terminals.
B A Tengage
TE
RY
The copper jaw contains
the smaller gauge wire that
reads the voltage and the
silver jaw contains the larger
conducting wire that draws
the load in each test. Jaw
insulation is necessary for
accurate readings. Damaged
clamps or loose wires will
affect the readings. Keep
clamps clean and in good
repair.
22
CHECK OFTEN FOR LOOSE JAWS
OR DAMAGED INTERNAL PLASTIC
SHOULDER INSULATORS
Low
Current
Jaw
High
Current
Jaw
LIMITED WARRANTY
Clore Automotive guarantees that this product to be free from defects in materials
and workmanship for a period of 1 Year (except for carbons and leads, which
are guaranteed for 90 days) from original date of purchase (dated sales receipt
required). This warranty extends to each person who acquires lawful ownership
within one year of the original retail purchase, but is void if the product has a
broken meter seal, has been abused, altered or misused, or has been improperly
packaged and damaged when returned for repair.
THE TERMS OF THE CLORE AUTOMOTIVE LIMITED WARRANTY
CONSTITUTE THE BUYER’S SOLE AND EXCLUSIVE REMEDY. THE IMPLIED
WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE ARE LIMITED IN DURATION TO THIS EXPRESS WARRANTY.
AFTER ONE YEAR FROM DATE OF PURCHASE, ALL RISK OF LOSS FROM
WHATEVER REASON SHALL BE PUT UPON THE PURCHASER.
CLORE AUTOMOTIVE SHALL NOT BE LIABLE FOR INCIDENTAL AND
CONSEQUENTIAL DAMAGES UNDER ANY CIRCUMSTANCES: CLORE
AUTOMOTIVE’S LIABILITY, IF ANY, SHALL NEVER EXCEED THE PURCHASE
PRICE OF THIS MACHINE REGARDLESS OF WHETHER LIABILITY IS
PREDICATED UPON BREACH OF WARRANTY (EXPRESS OR IMPLIED),
NEGLIGENCE, STRICT TORT OR ANY OTHER THEORY.
Some states do not permit the limitation of warranties or limitation of
consequential or incidental damages, so the above disclaimer and limitation may
not apply to you. This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
INSTRUCTIONS FOR OBTAINING SERVICE UNDER THIS WARRANTY:
If this product fails within one year due to a defect in material or workmanship, it
will be repaired or replaced, at Clore Automotive’s sole discretion, and retruned
freight prepaid. Send alleged defective product, properly packaged and freight
prepaid to the following address:
Clore Automotive
Warranty Service
8600 NE Underground Dr.
Kansas City, MO 64161
For answers to questions concerning use, out-of-warranty service, or warranty/
service information on this or other Clore Automotive products, contact:
Clore Automotive Technical Service
Kansas City, MO 64161
800.328.2921
913.310.1050
www.solaronline.com
23
Clore Automotive • Kansas City, MO 64161 • www.cloreautomotive.com • 913.310.1050
Warning: This product contains chemicals, including lead, known to the State of California to
cause cancer, birth defects and other reproductive harm. Wash hands after handling.
© 2006 Clore Automotive, 10/06
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