TECHNICAL SERVICE BULLETIN

Transcription

1 GROUP SST MODEL All Overview: File Under: <Special Service Tool> NUMBER DATE 023 (Rev 3, 10/03/2018) February 2011 TECHNICAL SERVICE BULLETIN This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin is being issued to identify battery, alternator, and starter diagnosis procedures and provide reference sections in the GR8 operations manual which was included in the GR8 tool shipment. KMA recommended that each dealer conduct an in-dealership technician training session showing correct diagnosis procedures outlined in the GR8 operation manual. The Kia Battery, Alternator, and Starter Warranty Policy requires the GR be used for all related warranty claims. o For battery replacement only warranty claims, the Kia Smart Battery Tester can also be used. Refer to Warranty Bulletins and for Warranty Policies posted on Kdealer.com (Fixed Ops Warranty Bulletins). Refer to TSB SST057 for detailed explanation of Test Recommendations regarding the Kia Smart Battery Tester. The GR must be used as part of the diagnosis for battery, alternator, and starter related warranty repair work. The GR is a state of the art tool that checks battery health and then performs a reliable intelligent safe charge which can quickly restore most batteries to good condition. Some dead batteries that have not been charged for a long period of time may be fully revived within 1.5 hours. Basic Operation and Battery Warranty Policy using GR8-1299: 1. The instruction Manual for the Midtronics GR can be found at the following location: Tools & Equipment Tool Information. 2. Perform a quick test in the Battery Test mode (see Page 2). If the Battery Test mode provides a Replace Battery result, with a replace code, the battery can be replaced without further steps. 3. If the Battery Test produces a Charge and Retest result, you are then required to conduct a Diagnostic Charge that will determine if the battery can be brought to a Good Battery condition. If the initial diagnostic charge test finds that the charge will not revive the battery, it will usually indicate Replace Battery within 20 to 30 minutes, on average (refer to page 25 of the GR8 Instruction Manual). 4. After conducting a Diagnostic Charge, ignore the test result after the charge and perform a second Battery Test after five (5) minutes. 5. Should the battery pass the Diagnostic Charge test, it will continue charging (in Top Off Mode) to a full charge condition (which can take up to 1.5 hours), and indicate Good Battery when completed successfully. Ignore the test result after the charge and perform a second Battery Test after five (5) minutes as mentioned in step 4 above. 6. The GR8 produces printouts of the results in both the Battery Test and Diagnostic Charge modes as well as for the starter and alternator. The printouts must be attached to the warranty repair order with proper VIN and RO number entered via GR8 s keyboard. Note: The GR8 diagnosis procedure requires that the technician always performs a Diagnostic Charge after a Battery Test result of Charge and Retest. Ignore the test result after the Diagnostic charge after perform a second Battery Test after five (5) minutes as mentioned in step 4 above. Circulate To: Ẍ General Manager Ẍ Service Manager Ẍ Parts Manager Ẍ Service Advisors X Technicians Ẍ Body Shop Manager Ẍ Fleet Repair

2 Page 2 of 10 GR Battery, Starting, and Charging Systems Test Unit: Performs Battery, Starting, and Charging Systems testing and diagnostic charging. The GR8 Control Module can be used independently of the Charge Engine after a battery charge session is in process. The Quick Disconnect Serial Cable from the Charge Engine to the Control Module may be disconnected and maintain wireless communication between the Control Module and Charge Engine. The Quick Disconnect Serial Cable should be reconnected when docked on the Charge Engine. Charge Engine Control Module CAUTION Never connect both the Control Module Clamps and Charge Engine Clamps to a battery at the same time. Damage to the Control Module may occur. Service Procedure: The battery inspection is a three-step process, Battery Test and if required, Diagnostic Charge and second Battery Test. Result: Good Battery No further action required. Initial Battery Test Performed. Result: Diagnostic Charge Required (Charge & Retest) Perform Diagnostic Charge. Ignore initial test result from Diagnostic Charge. Wait five (5) minutes. Perform second Battery Test. Result: Replace Battery Replace battery. IMPORTANT After charging the battery (Diagnostic Charge), ignore the test result after the charge and perform a second Battery Test after five (5) minutes. Print the second test result.

3 Page 3 of 10 Battery Test, STEP ONE (Refer to page 25 in the GR Instruction Manual): Power on the GR8 with the Control Module docked on the Charge Engine. You should hear the fan come on and Control Module display will light up. 1. Connect the Control Module's small clamps to the vehicle s battery. Ensure that the black clamp is connected to the battery negative - terminal and the red clamp is connected to the battery positive + terminal. The GR8 will display a warning if the terminals are connected backwards. Do not use jump start posts for battery testing. Always use the battery posts. 2. Select Battery Test. Follow the tester instructions to complete the battery test. 3. Follow these screen by screen instructions from left to right of each row. This example shows screens that will occur for battery condition of Charge & Retest : Enter last 6 digits of VIN Select IN/OUT of vehicle* Select CUSTOMER CAR Make sure to hold the tester 2 above the battery, as described in the step below, in order to ensure maximum accuracy when reading the battery temperature. Select FLOODED battery type Enter CCA rating of battery Select Next Testing is in process Enter Repair Order number Test Result. Print for the R.O. *Battery policy is to test all batteries "in vehicle".

4 Page 4 of 10 All Kia replacement batteries for warranty claims are supplied by Interstate as per the Battery Application Guide located at Publication PDI & Eval Docs. This application guide can be referenced for the proper CCA rating per model for test purposes. KMA provides warranty coverage only for Genuine Kia Batteries purchased from KMA. Refer to section 7.21 of the Kia Service Policy & Procedures Manual. Always print out the Battery Test result to attach to the Repair Order or retailed vehicles. During PDI the battery test strip must be attached to the PDI delivery form. 4. Follow directions provided in the following table based on result of Battery Test (first column). print results at Battery Test and then after Diagnostic Charge (**see note below): GR8 Battery Diagnostic Test / Charge Repair Procedure & Warranty Policy 1 st Step 2 nd Step 3 rd Step Always begin with a battery test first: Perform diagnostic charge as applicable. Press YES or select Diagnostic at Main Menu: See table below. **NOTE: After charging the battery with the GR8, ignore the test result after the charge and perform a second Battery Test after five (5) minutes. Print the second test result. See flow chart on page 2. Battery Test Result Diag. Charge Result Repair Action Warranty Claim Type Good Battery Charge is not applicable None None Good Recharge Charge Battery Charge using GR8 + Perform second Battery Test after 5 minutes (**see note above). Retailed vehicle 37110A00 (Add to R.O. Print Ticket #A) Dealer Stock: None Replace battery/bad cell Charge is not applicable Replace Battery Replace 37110R00 only (Add to R.O. Print Ticket #A) Charge & Retest Perform second Battery Test after 5 minutes (**see note above). GR8 Charge Only OEM Batteries covered for 2 years/unlimited miles. Charge 37110A0A / 37110A00 only (Add to R.O. Print Ticket #B) Charge 37110A0A / 37110A00 + Repalce 37110R00 (Add to R.O. Print Ticket #C) Charge & Retest Perform second Battery Test after 5 minutes (**see note above). GR8 Charge attempt: No good Replace battery.

5 Page 5 of 10 Diagnostic Charge, STEP TWO, if instructed by GR8 (Refer to page 21 in the GR Instruction Manual): 5. Connect only the Charger Engine s large clamp set to the vehicle s battery making sure that the black clamp is connected to the battery negative - terminal and the red clamp is connected to the battery positive + terminal. NOTE: The GR8 will display a warning if the terminals are connected backwards. 6. Perform the following instructions showing the GR8 screens (as shown from left to right of each row). Below is what will occur when a Good Battery is reached after charging: Press YES to start Charging Connect large clamps Diagnostic Charge is in Process: Charge status being displayed Good Battery condition reached Full charge complete 6a. Ignore the Good Battery test result after the charge and perform a second Battery Test after five (5) minutes. When the second test results in Good Battery, you must attach the printed test results from both Battery Test with the Charge & Retest result and the second test s Good Battery result per example of Print Ticket #B on the page Below is what will occur on the GR8 screen when Replace Battery results after a Diagnostic Charge attempt: Charge status being displayed Enter R.O. Number Charge NG Replace Battery

6 Page 6 of 10 7a. Ignore the Replace Battery test result after the charge and perform a second Battery Test after five (5) minutes. When the second test results in Replace Battery, you may in this circumstance be permitted to claim Op Code 37110A0A/37110A00 for the Charge Battery attempt and also Op Code 37110R00 for Replace Battery. However, you must attach the printed test results from both Battery Test with the Charge & Retest result and second test result showing Replace Battery per example of Print Ticket #C below. For battery replacements under warranty, refer to Warranty Bulletin for Warranty Replacement requirements. 8. Print Tickets that must be attached to the Repair Order based on initial and second (after Diagnostic Charge) Battery Test results are shown below. Also listed are the warranty claim types. Print Ticket #A REPLACE 37110R00 ONLY BATTERY TEST= REPLACE BATTERY Print Ticket #B (Both tickets as shown must be attached with matching VIN, close in date, and with correct R.O.#) CHARGE 37110A0A/37110A00 ONLY Print Ticket #C (Both tickets as shown must be attached with matching VIN, close in date, and with correct R.O.#) CHARGE 37110A0A/37110A00 + REPLACE 37110R00 1. BATTERY TEST = CHARGE & RETEST 1. BATTERY TEST = CHARGE & RETEST 2. 2 ND BATTERY TEST AFTER DIAGNOSTIC CHARGE = GOOD BATTERY 2. 2 ND BATTERY TEST AFTER DIAGNOSTIC CHARGE = REPLACE BATTERY Enter this 12-digit warranty code into the claim based on results as indicated.

7 Page 7 of 10 All Kia replacement batteries for warranty claims are supplied by Interstate as per the Battery Application Guide located at Publication PDI & Eval Docs. This application guide can be referenced for the proper CCA rating per model for test purposes. KMA provides warranty coverage only for Genuine Kia Batteries purchased from KMA. Refer to section 7.21 of the Kia Service Policy & Procedures Manual. The System Test (Refer to page 28 in the GR Instruction Manual): The GR8 System Test checks the status of the Battery, Starting and Charging systems. Before replacing components, verify integrity of circuits and cables. 1. Connect the Control Module clamps to the vehicle s battery. Ensure that the black clamp is connected to the battery negative - terminal and the red clamp is connected to the battery positive + terminal. NOTE: The GR8 will display a warning if the terminals are connected backwards. 2. Select System Test". 3. The GR8 Control Module will perform a Battery Test. Follow procedure found under Battery Test, STEP ONE (Page 2 of this TSB) (Refer to page 25 in the GR Instruction Manual).

8 Page 8 of The Starter Test (Refer to page 30 in the GR Instruction Manual): Follow the instructions on the screen to complete the starter test. When asked to start the engine, do NOT disable the ignition or fuel. The starting system is tested while the engine is started. Before replacing the starter, check the cables. If the vehicle is a NO CRANK/NO START, the tester will ask you to select between "STARTED" and "NO START". After selecting "NO START", the tester will produce a Starter Code. The test results will be displayed. The use of an Amp Clamp is not required. When asked if one is being used, select NOT AVAILABLE. Using an amp clamp will not affect test results. 5. The Charging System Test (Refer to page 31 in the GR Instruction Manual): Follow the instructions on the screen to complete the charging test. The tech will be asked to run the engine at different RPM with and without loads. When complete, the tester will display the results. Before replacing the alternator, check the wiring and cables along with the charge signal from the ECM.

9 FAQ s Q: Page 9 of 10 The Midtronics GR tester did not produce a code. How do I enter a warranty claim? A: Q: A: When the procedure is followed properly, the Midtronics GR tester will always produce a code. To determine the cause, the technician should read the GR8 Instruction Manual and this TSB. The vehicle was towed into the shop and would not crank and start. How can I get a code to enter a warranty claim? The technician should run a GR8 System Test to diagnosis the battery, alternator or starter. During the starter test portion, he should input No Start into the tester. If the battery is good the tester will show No Start and produce a code.

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