Optima batteries have had some problems since they moved their production facilities out of the country. For a quick check of the rest of the system, try a boost start with a 12 volt battery. If the starter runs well, the problem is almost sure to be the battery.
Another method of checking is to measure the battery terminal voltage as the starter is trying to run. If it's below 4.5 volts with the starter engaged, REPLACE THE BATTERY! You have tried repeatedly to charge it, and it's obvious it's not doing the job. Maybe Optima will take it back as a defective unit, depending on how long you've owned it, but I wouldn't trust any battery that I can't open up and check the concentration of the acid. If there is a heavy truck electrical supplier somewhere in your area, see if they can still get one of the 6-volt batteries we used to install in series-parallel truck electrical systems. They're about 50% larger than a stovebolt battery and they have much higher cranking amp capacity. You'll need to enlarge the battery box to accomodate the bigger battery case.
Jerry
Edit: I found a battery on the Optima website that has an 800 Cold Cranking Amp rating, which should be tested at 400 amps. Take the battery to someone with a professional-quality tester that can put a 400 amp load on it for 15 seconds. I'm sure you'll find a bad battery.
Jerry
Last edited by Hotrod Lincoln; 04/12/2011 3:14 AM.
